ServiceManual - RAWRATS.COM · This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics.

3C5-28197-10

XT250X

XT250XC

SERVICE MANUAL

LIT-11616-21-52

2008

EAS20050

XT250XXT250XC

SERVICE MANUAL©2008 by Yamaha Motor Corporation, U.S.A.

First edition, August 2007All rights reserved.

Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited.Printed in U.S.A.

P/N LIT-11616-21-52

EAS20070

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehiclesshould have a basic understanding of mechanics and the techniques to repair these types of vehicles.Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-cle unsafe and unfit for use.This model has been designed and manufactured to perform within certain specifications in regard toperformance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-cle will operate as designed. If there is any question about a service procedure, it is imperative that youcontact a Yamaha dealer for any service information changes that apply to this model. This policy isintended to provide the customer with the most satisfaction from his vehicle and to conform to federalenvironmental quality objectives.Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable.NOTE:

This Service Manual contains information regarding periodic maintenance to the emission controlsystem. Please read this material carefully.

Designs and specifications are subject to change without notice.

EAS20080

IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order. The manual is divided into chapters and each chapter is divided into sections. The current section title

is shown at the top of each page “1”. Sub-section titles appear in smaller print than the section title “2”. To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section “3”. Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassem-

bly step “4”. Symbols indicate parts to be lubricated or replaced “5”.Refer to “SYMBOLS”. A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc “6”. Jobs requiring more information (such as special tools and technical data) are described sequentially

“7”.

7

2

CLUTCH

5-31

Removing the clutch

Order Job/Parts to remove Q’ty Remarks

1 Clutch spring 5

2 Pressure plate 1

3 Adjusting screw 1

4 Push plate 1

5 Friction plate 6

6 Clutch plate 5

7 Clutch damper spring 1

8 Clutch damper spring seat 1

9 Primary drive gear nut 1

10 Lock washer 1

11 Claw washer 1

12 Clutch boss nut 1

13 Lock washer 1

14 Clutch boss 1

15 Thrust washer 1

16 Clutch housing 1

17 Ball 1

18 Clutch push rod 1

19 Primary drive gear 1

For installation, reverse the removal proce-dure.

New

New

E

TR..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

TR..

75 Nm (7.5 m • kg, 54 ft • Ib)

TR..

80 Nm (8.0 m • kg, 58 ft • Ib)

1

2

56

78

12

13

15

1617

910

1119

18

14

34

(5)

3

4

5

6

1

CLUTCH

5-33

EAS25070

REMOVING THE CLUTCH1. Straighten the lock washer tab.2. Loosen:

Primary drive gear nut “1”NOTE:

Insert aluminum plate “a” between primary drivegear “2” and primary driven gear “3”, and loosenthe primary drive gear nut.

3. Loosen:Clutch boss nut “1”

NOTE:

While holding the clutch boss “1” with the univer-sal clutch holder “2”, loosen the clutch boss nut.

EAS25100

CHECKING THE FRICTION PLATESThe following procedure applies to all of the fric-tion plates.1. Check:

Friction plateDamage/wear Replace the friction platesas a set.

2. Measure:Friction plate thicknessOut of specification Replace the frictionplates as a set.

NOTE:

Measure the friction plate at four places.

EAS25110

CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check:

Clutch plateDamage Replace the clutch plates as aset.

2. Measure:Clutch plate warpage(with a surface plate and thickness gauge “1”)Out of specification Replace the clutchplates as a set.

EAS25140

CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of theclutch springs.1. Check:

Clutch springDamage Replace the clutch springs as aset.

2. Measure:

Universal clutch holder90890-04086YM-91042

2

1 3

Friction plate thickness2.70—2.90 mm (0.106—0.114 in)

Wear limit2.60 mm (0.1024 in)

Warpage limit0.20 mm (0.0079 in)

EAS20100

SYMBOLS

The following symbols are used in this manualfor easier understanding.NOTE:

The following symbols are not relevant to everyvehicle.

G

M

E

B LS

M

9 10

11 12

13 14

15 16

17 18

LT New

BF

S

TR

..

1 2 3

4 5 6

7 8

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10. Gear oil

11. Molybdenum-disulfide oil

12. Brake fluid

13. Wheel-bearing grease

14. Lithium-soap-based grease

15. Molybdenum-disulfide grease

16. Silicone grease

17. Apply locking agent (LOCTITE®)

18. Replace the part

GENERAL INFORMATION 1

SPECIFICATIONS 2

PERIODIC CHECKS ANDADJUSTMENTS 3

CHASSIS 4

ENGINE 5

FUEL SYSTEM 6

ELECTRICAL SYSTEM 7

TROUBLESHOOTING 8

EAS20110

TABLE OF CONTENTS

1

2

3

4

5

6

7

8

9

GENERAL INFORMATION

IDENTIFICATION ...........................................................................................1-1VEHICLE IDENTIFICATION NUMBER....................................................1-1MODEL LABEL ........................................................................................1-1

IMPORTANT INFORMATION ........................................................................1-2PREPARATION FOR REMOVAL AND DISASSEMBLY .........................1-2REPLACEMENT PARTS .........................................................................1-2GASKETS, OIL SEALS AND O-RINGS...................................................1-2LOCK WASHERS/PLATES AND COTTER PINS....................................1-2BEARINGS AND OIL SEALS...................................................................1-2CIRCLIPS.................................................................................................1-3

CHECKING THE CONNECTIONS.................................................................1-4

SPECIAL TOOLS...........................................................................................1-5

IDENTIFICATION

1-1

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number “1” is stampedinto the right side of the steering head pipe.

EAS20150

MODEL LABELThe model label “1” is affixed to the frame. Thisinformation will be needed to order spare parts.

1

1

IMPORTANT INFORMATION

1-2

EAS20180


EAS20190

PREPARATION FOR REMOVAL AND DISASSEMBLY1. Before removal and disassembly, remove all

dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning equip-ment.Refer to “SPECIAL TOOLS” on page 1-5.

3. When disassembling, always keep matedparts together. This includes gears, cylin-ders, pistons and other parts that have been“mated” through normal wear. Mated partsmust always be reused or replaced as an as-sembly.

4. During disassembly, clean all of the parts andplace them in trays in the order of disassem-bly. This will speed up assembly and allow forthe correct installation of all parts.

5. Keep all parts away from any source of fire.

EAS20200

REPLACEMENT PARTSUse only genuine Yamaha parts for all replace-ments. Use oil and grease recommended byYamaha for all lubrication jobs. Other brandsmay be similar in function and appearance, butinferior in quality.

EAS20210

GASKETS, OIL SEALS AND O-RINGS1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket surfac-es, oil seal lips and O-rings must be cleaned.

2. During reassembly, properly oil all matingparts and bearings and lubricate the oil seallips with grease.

EAS20220

LOCK WASHERS/PLATES AND COTTER PINSAfter removal, replace all lock washers/plates“1” and cotter pins. After the bolt or nut has beentightened to specification, bend the lock tabsalong a flat of the bolt or nut.

EAS20230

BEARINGS AND OIL SEALSInstall bearings and oil seals so that the manu-facturer’s marks or numbers are visible. Wheninstalling oil seals “1”, lubricate the oil seal lipswith a light coat of lithium-soap-based grease.Oil bearings liberally when installing, if appropri-ate.


1-3

CAUTION:

ECA13300

Do not spin the bearing with compressed airbecause this will damage the bearing surfac-es.

EAS20240

CIRCLIPSBefore reassembly, check all circlips carefullyand replace damaged or distorted circlips. Al-ways replace piston pin clips after one use.When installing a circlip “1”, make sure thesharp-edged corner “2” is positioned oppositethe thrust “3” that the circlip receives.

CHECKING THE CONNECTIONS

1-4

EAS20250

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect:

Lead Coupler Connector

2. Check: Lead Coupler Connector

Moisture → Dry with an air blower.Rust/stains → Connect and disconnect sev-eral times.

3. Check: All connections

Loose connection → Connect properly.NOTE:

If the pin “1” on the terminal is flattened, bend itup.

4. Connect: Lead Coupler Connector

NOTE:

Make sure all connections are tight.

5. Check: Continuity

(with the pocket tester)

NOTE:

If there is no continuity, clean the terminals. When checking the wire harness, perform

steps (1) to (3). As a quick remedy, use a contact revitalizer

available at most part stores.

Pocket tester90890-03132

SPECIAL TOOLS

1-5

EAS20260

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appropriate special tools as this will help prevent damage caused by the use of inappropriate toolsor improvised techniques. Special tools, part numbers or both may differ depending on the country.When placing an order, refer to the list provided below to avoid any mistakes.NOTE:

For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.For others, use part number starting with “90890-”.

Tool name/Tool No. IllustrationReference

pages


1-4, 3-7, 3-8,5-52, 7-35,7-36, 7-37,7-40, 7-41,7-42, 7-43,7-44, 7-45, 7-47

Special thickness gauge90890-01399

3-5

Tappet adjusting tool90890-01311Six piece tappet setYM-A5970

3-6

Digital tachometer90890-06760YU-39951-B

3-7, 3-8, 3-11

Timing light90890-03141Inductive clamp timing lightYU-03141

3-11

Compression gauge90890-03081Engine compression testerYU-33223

3-12

SPECIAL TOOLS

1-6

Steering nut wrench90890-01403Spanner wrenchYU-33975

3-23

Ring nut wrench90890-01268Spanner wrenchYU-01268

3-24, 4-49

Spoke wrench90890-01522

3-27

Cylinder cup installer90890-01996

4-22, 4-33

Damper rod holder90890-01460

4-42, 4-44

T-handle90890-01326T-handle 3/8" drive 60 cm longYM-01326

4-44

Fork seal driver weight90890-01367Replacement hammerYM-A9409-7

4-44, 4-45


pages

YM-A9409-7/YM-A5142-4

SPECIAL TOOLS

1-7

Fork seal driver attachment (ø35)90890-01369Replacement 35 mmYM-A9409-5

4-44

Slide hammer bolt90890-01083Slide hammer bolt 6 mmYU-01083-1

5-14

Weight90890-01084YU-01083-3

5-14

Valve spring compressor90890-04019YM-04019

5-18, 5-23

Valve guide remover (ø6)90890-04064Valve guide remover (6.0 mm)YM-04064-A

5-20

Valve guide installer (ø6)90890-04065Valve guide installer (6.0 mm)YM-04065-A

5-20

Valve guide reamer (ø6)90890-04066Valve guide reamer (6.0 mm)YM-04066

5-20


pages

YU-01083-3

SPECIAL TOOLS

1-8


5-33, 5-35

Sheave holder90890-01701Primary clutch holderYS-01880-A

5-47, 5-48

Flywheel puller90890-01362Heavy duty pullerYU-33270-B

5-47

Yamaha bond No. 1215 (Three Bond No.1215®)90890-85505

5-56

Crankcase separating tool90890-01135Crankcase separatorYU-01135-B

5-59


pages

SPECIAL TOOLS

1-9

Crankshaft installer pot90890-01274Installing potYU-90058

5-60

Crankshaft installer bolt90890-01275BoltYU-90060

5-60

Adapter (M10)90890-01383Adapter #2YU-90062

5-60

Spacer90890-01288

5-60

Ignition checker90890-06754Opama pet-4000 spark checkerYM-34487

7-43

Digital circuit tester90890-03174Model 88 Multimeter with tachometerYU-A1927

7-46


pages

YU-90058/YU-90059

1

2

3

4

5

6

7

8

9

SPECIFICATIONS

GENERAL SPECIFICATIONS .......................................................................2-1

ENGINE SPECIFICATIONS...........................................................................2-2

CHASSIS SPECIFICATIONS.........................................................................2-9

ELECTRICAL SPECIFICATIONS..................................................................2-11

TIGHTENING TORQUES...............................................................................2-13GENERAL TIGHTENING TORQUE SPECIFICATIONS..........................2-13ENGINE TIGHTENING TORQUES..........................................................2-13CHASSIS TIGHTENING TORQUES........................................................2-15

LUBRICATION POINTS AND LUBRICANT TYPES .....................................2-18ENGINE....................................................................................................2-18CHASSIS..................................................................................................2-19

LUBRICATION SYSTEM CHART AND DIAGRAMS ....................................2-21ENGINE OIL LUBRICATION CHART ......................................................2-21LUBRICATION DIAGRAMS.....................................................................2-23

CABLE ROUTING..........................................................................................2-25

GENERAL SPECIFICATIONS

2-1

EAS20280

GENERAL SPECIFICATIONS

ModelModel 3C58 (U49)

3C59 (CAL)

DimensionsOverall length 2150 mm (84.6 in)Overall width 805 mm (31.7 in)Overall height 1160 mm (45.7 in)Seat height 810 mm (31.9 in)Wheelbase 1360 mm (53.5 in)Ground clearance 285 mm (11.22 in)Minimum turning radius 1900 mm (74.8 in)

WeightWith oil and fuel 132.0 kg (291 lb)Maximum load 160.0 kg (353 lb)

ENGINE SPECIFICATIONS

2-2

EAS20290


EngineEngine type Air cooled 4-stroke, SOHCDisplacement 249.0 cm3

Cylinder arrangement Forward-inclined single cylinderBore × stroke 74.0 × 58.0 mm (2.91 × 2.28 in)Compression ratio 9.50 :1Starting system Electric starter

FuelRecommended fuel Unleaded gasoline onlyFuel tank capacity 9.1 L (2.40 US gal) (2.00 Imp.gal) (CAL)

9.8 L (2.59 US gal) (2.16 Imp.gal) (U49)Fuel reserve amount 1.9 L (0.50 US gal) (0.42 Imp.gal)

Engine oilLubrication system Wet sumpType YAMALUBE 4, SAE10W30 or SAE20W40Recommended engine oil grade API service SG type or higher, JASO standard

MAEngine oil quantity

Total amount 1.40 L (1.48 US qt) (1.23 Imp.qt)Without oil filter element replacement 1.20 L (1.27 US qt) (1.06 Imp.qt)With oil filter element replacement 1.30 L (1.37 US qt) (1.14 Imp.qt)Oil filter type Paper

Oil pumpOil pump type TrochoidInner-rotor-to-outer-rotor-tip clearance 0.150 mm (0.0059 in)Limit 0.200 mm (0.0079 in)Outer-rotor-to-oil-pump-housing clearance 0.100–0.151 mm (0.0039–0.0059 in)Limit 0.221 mm (0.0087 in)Oil-pump-housing-to-inner-and-outer-rotor clearance 0.04–0.09 mm (0.0016–0.0035 in)Limit 0.16 mm (0.0063 in)Pressure check location HEAD CYLINDER

Spark plug (s)Manufacturer/model NGK/DR7EASpark plug gap 0.6–0.7 mm (0.024–0.028 in)

Cylinder headVolume 20.50–21.50 cm3 (1.25–1.31 cu.in)Warpage limit 0.03 mm (0.0012 in)

CamshaftDrive system Chain drive (right)Camshaft journal diameter 25.021–25.039 mm (0.9851–0.9858 in)


2-3

Camshaft lobe dimensions

Intake A 36.520–36.620 mm (1.4378–1.4417 in)Limit 36.460 mm (1.4354 in)Intake B 30.201–30.301 mm (1.1890–1.1930 in)Limit 30.151 mm (1.1870 in)Exhaust A 36.564–36.664 mm (1.4395–1.4435 in)Limit 36.514 mm (1.4376 in)Exhaust B 30.216–30.316 mm (1.1896–1.1935 in)Limit 30.166 mm (1.1876 in)

Camshaft runout limit 0.030 mm (0.0012 in)

Timing chainModel/number of links DID SCR-0404 SV/104Tensioning system Automatic

Rocker arm/rocker arm shaftRocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in)Limit 12.036 mm (0.4739 in)Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in)Limit 11.950 mm (0.4705 in)Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004–0.0015 in)

Valve, valve seat, valve guideValve clearance (cold)

Intake 0.05–0.10 mm (0.0020–0.0039 in)Exhaust 0.10–0.15 mm (0.0039–0.0059 in)

Valve dimensions

Valve head diameter A (intake) 33.90–34.10 mm (1.3346–1.3425 in)Valve head diameter A (exhaust) 28.40–28.60 mm (1.1181–1.1260 in)

Valve face width B (intake) 2.260 mm (0.0890 in)Valve face width B (exhaust) 2.260 mm (0.0890 in)

Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)

A

B

A

B


2-4

Valve margin thickness D (intake) 0.80–1.20 mm (0.0315–0.0472 in)Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in)

Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in)Limit 5.950 mm (0.2343 in)Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in)Limit 5.935 mm (0.2337 in)Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in)Limit 6.042 mm (0.2379 in)Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in)Limit 6.042 mm (0.2379 in)Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)Limit 0.080 mm (0.0032 in)Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)Limit 0.100 mm (0.0039 in)Valve stem runout 0.030 mm (0.0012 in)

Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)Limit 1.7 mm (0.07 in)Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)Limit 1.7 mm (0.07 in)

Valve springInner spring

Free length (intake) 36.17 mm (1.42 in)Limit 34.47 mm (1.36 in)Free length (exhaust) 36.17 mm (1.42 in)Limit 34.47 mm (1.36 in)Installed length (intake) 30.50 mm (1.20 in)Installed length (exhaust) 30.50 mm (1.20 in)Spring rate K1 (intake) 14.70 N/mm (83.94 lb/in) (1.50 kgf/mm)Spring rate K2 (intake) 19.00 N/mm (108.49 lb/in) (1.94 kgf/mm)Spring rate K1 (exhaust) 14.70 N/mm (83.94 lb/in) (1.50 kgf/mm)Spring rate K2 (exhaust) 19.00 N/mm (108.49 lb/in) (1.94 kgf/mm)Installed compression spring force (intake) 75.00–91.70 N (16.86–20.61 lbf) (7.65–9.35 kgf)Installed compression spring force (exhaust) 75.00–91.70 N (16.86–20.61 lbf) (7.65–9.35 kgf)Spring tilt (intake) 2.5 °/1.6 mmSpring tilt (exhaust) 2.5 °/1.6 mm

C

D


2-5

Winding direction (intake) Counter clockwiseWinding direction (exhaust) Counter clockwise

Outer spring

Free length (intake) 36.63 mm (1.44 in)Limit 34.63 mm (1.36 in)Free length (exhaust) 36.63 mm (1.44 in)Limit 34.63 mm (1.36 in)Installed length (intake) 32.00 mm (1.26 in)Installed length (exhaust) 32.00 mm (1.26 in)Spring rate K1 (intake) 30.90 N/mm (176.44 lb/in) (3.15 kgf/mm)Spring rate K2 (intake) 40.80 N/mm (232.97 lb/in) (4.16 kgf/mm)Spring rate K1 (exhaust) 30.90 N/mm (176.44 lb/in) (3.15 kgf/mm)Spring rate K2 (exhaust) 40.80 N/mm (232.97 lb/in) (4.16 kgf/mm)Installed compression spring force (intake) 128.50–157.90 N (28.89–35.50 lbf)

(13.10–16.10 kgf)Installed compression spring force (exhaust) 128.50–157.90 N (28.89–35.50 lbf)

(13.10–16.10 kgf)Spring tilt (intake) 2.5 °/1.6 mmSpring tilt (exhaust) 2.5 °/1.6 mm

Winding direction (intake) ClockwiseWinding direction (exhaust) Clockwise

CylinderBore 74.000–74.016 mm (2.9134–2.9140 in)Wear limit 74.100 mm (2.9173 in)Taper limit 0.050 mm (0.0020 in)Out of round limit 0.010 mm (0.0004 in)Warp limit 0.10 mm (0.0039 in)

PistonPiston-to-cylinder clearance 0.010–0.025 mm (0.0004–0.0010 in)Limit 0.15 mm (0.0059 in)Diameter D 73.983–73.998 mm (2.9127–2.9133 in)Height H 11.0 mm (0.43 in)


2-6

Offset 0.50 mm (0.0197 in)Offset direction Intake sidePiston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)Limit 16.043 mm (0.6316 in)Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)Limit 15.971 mm (0.6288 in)Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)

Piston ringTop ring

Ring type BarrelDimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in)

End gap (installed) 0.19–0.31 mm (0.0075–0.0122 in)Limit 0.56 mm (0.0220 in)Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)Limit 0.115 mm (0.0045 in)

2nd ring

Ring type TaperDimensions (B × T) 0.80 × 2.80 mm (0.03 × 0.11 in)

End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in)Limit 0.80 mm (0.0314 in)Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)Limit 0.115 mm (0.0045 in)

Oil ring

Dimensions (B × T) 1.50 × 2.60 mm (0.06 × 0.10 in)

End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in)

H

D

T

B

B

T

B

T


2-7

CrankshaftWidth A 69.25–69.30 mm (2.726–2.728 in)Runout limit C 0.030 mm (0.0012 in)Big end side clearance D 0.350–0.850 mm (0.0138–0.0335 in)

BalancerBalancer drive method Gear

ClutchClutch type Wet, multiple-discClutch release method Inner push, cam pushClutch lever free play 10.0–15.0 mm (0.39–0.59 in)Friction plate thickness 2.70–2.90 mm (0.106–0.114 in)Wear limit 2.60 mm (0.1024 in)Plate quantity 6 pcsClutch plate thickness 1.50–1.70 mm (0.059–0.067 in)Plate quantity 5 pcsWarpage limit 0.20 mm (0.0079 in)Clutch spring free length 40.10 mm (1.58 in)Limit 38.10 mm (1.50 in)Spring quantity 5 pcsClutch housing thrust clearance 0.100–0.350 mm (0.0039–0.0138 in)Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in)Push rod bending limit 0.500 mm (0.0197 in)

TransmissionTransmission type Constant mesh 5-speedPrimary reduction system Spur gearPrimary reduction ratio 74/24 (3.083)Secondary reduction system Chain driveSecondary reduction ratio 48/15 (3.200)Operation Left foot operationGear ratio

1st 37/13 (2.846)2nd 29/16 (1.812)3rd 29/22 (1.318)4th 29/28 (1.035)5th 23/28 (0.821)

Main axle runout limit 0.08 mm (0.0032 in)Drive axle runout limit 0.08 mm (0.0032 in)Main axle assembly width 102.20–102.40 mm (4.02–4.03 in)

Shifting mechanismShift mechanism type Shift drum and guide barShift fork thickness 4.76–4.89 mm (0.1874–0.1925 in)

CC

D

A


2-8

Air filterAir filter element Oil-coated paper element

CarburetorType × quantity MV33 x 1Manufacturer TEIKEIID mark 3C58 00 (U49)

3C59 00 (CAL)Main jet #135Main air jet 1.20Jet needle 5A21-1Needle jet 2.585Pilot air jet 1 0.90Pilot outlet 0.8x1.2Pilot jet #34Bypass 1 0.8Bypass 2 0.8Bypass 3 0.8Bypass 4 0.8Pilot screw turn out 2–1/2Valve seat size 0.50Starter jet 1 #90Starter jet 2 #78Throttle valve size 33Float height 11.9 mm (0.47 in)

Idling conditionEngine idling speed 1300–1500 r/minCO% 0.5–1.5 %Intake vacuum 29.0–37.0 kPa (8.6–10.9 inHg) (218–278 mm-

Hg)Oil temperature 95.0–105.0

°C (203.00–221.00

°F)Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)

CHASSIS SPECIFICATIONS

2-9

EAS20300


ChassisFrame type Semi double cradleCaster angle 26.42 °Trail 106.0 mm (4.17 in)

Front wheelWheel type Spoke wheelRim size 21x1.60Rim material AluminumWheel travel 225.0 mm (8.86 in)Radial wheel runout limit 2.0 mm (0.08 in)Lateral wheel runout limit 2.0 mm (0.08 in)Wheel axle bending limit 0.25 mm (0.01 in)

Rear wheelWheel type Spoke wheelRim size 18M/C x MT2.15Rim material AluminumWheel travel 180.0 mm (7.09 in)Radial wheel runout limit 2.0 mm (0.08 in)Lateral wheel runout limit 2.0 mm (0.08 in)Wheel axle bending limit 0.25 mm (0.01 in)

Front tireType With tubeSize 2.75-21 45PManufacturer/model CHENG SHIN/C-6006Manufacturer/model DUNLOP/D605FWear limit (front) 0.8 mm (0.03 in)

Rear tireType With tubeSize 120/80-18M/C 62PManufacturer/model CHENG SHIN/C-6006Manufacturer/model DUNLOP/D605Wear limit (rear) 0.8 mm (0.03 in)

Tire air pressure (measured on cold tires)Loading condition 0–90 kg (0–198 lb)Front 125 kPa (18 psi) (1.25 kgf/cm2)Rear 150 kPa (22 psi) (1.50 kgf/cm2)Loading condition 90 kg–Maximum loadFront 150 kPa (22 psi) (1.50 kgf/cm2)Rear 175 kPa (25 psi) (1.75 kgf/cm2)

Front brakeType Single disc brakeOperation Right hand operationFront brake lever free play 2.0–5.0 mm (0.08–0.20 in)Front disc brake

Disc outside diameter × thickness 245.0 × 3.5 mm (9.65 × 0.14 in)Brake disc thickness limit 3.0 mm (0.12 in)


2-10

Brake disc deflection limit 0.15 mm (0.0059 in)Brake pad lining thickness (inner) 5.3 mm (0.21 in)Limit 0.8 mm (0.03 in)Brake pad lining thickness (outer) 5.3 mm (0.21 in)Limit 0.8 mm (0.03 in)Master cylinder inside diameter 11.00 mm (0.43 in)Caliper cylinder inside diameter 26.99 mm (1.06 in)Caliper cylinder inside diameter 22.22 mm (0.87 in)Recommended fluid DOT 4

Rear brakeType Single disc brakeOperation Right foot operationBrake pedal position 20.0 mm (0.79 in)Rear disc brake

Disc outside diameter × thickness 203.0 × 4.5 mm (7.99 × 0.18 in)Brake disc thickness limit 4.0 mm (0.16 in)Brake disc deflection limit 0.15 mm (0.0059 in)Brake pad lining thickness (inner) 5.2 mm (0.20 in)Limit 1.0 mm (0.04 in)Brake pad lining thickness (outer) 5.2 mm (0.20 in)Limit 1.0 mm (0.04 in)Master cylinder inside diameter 12.7 mm (0.50 in)Caliper cylinder inside diameter 30.23 mm (1.19 in)Recommended fluid DOT 4

SteeringSteering bearing type Taper roller bearingCenter to lock angle (left) 51.0 °Center to lock angle (right) 51.0 °

Front suspensionType Telescopic forkSpring/shock absorber type Coil spring/oil damperFront fork travel 225.0 mm (8.86 in)Fork spring free length 482.0 mm (18.98 in)Limit 472.3 mm (18.59 in)Installed length 472.2 mm (18.59 in)Spring rate K1 3.65 N/mm (20.84 lb/in) (0.37 kgf/mm)Spring stroke K1 0.0–225.0 mm (0.00–8.86 in)Optional spring available NoRecommended oil Yamaha fork oil 15WTQuantity 385.0 cm3 (13.02 US oz) (13.58 Imp.oz)Level 125.0 mm (4.92 in)

SwingarmSwingarm end free play limit (radial) 1.0 mm (0.04 in)Swingarm end free play limit (axial) 1.0 mm (0.04 in)

Drive chainType/manufacturer 428V/DAIDOLink quantity 128Drive chain slack 40.0–45.0 mm (1.57–1.77 in)15-link length limit 191.5 mm (7.54 in)

ELECTRICAL SPECIFICATIONS

2-11

EAS20310


VoltageSystem voltage 12 V

Ignition systemIgnition system CDIAdvancer type DigitalIgnition timing (B.T.D.C.) 10.0 °/1400 r/min

CDIMagneto model/manufacturer F5XT/YAMAHAPickup coil resistance 248–372 Ω (Red–white)CDI unit model/manufacturer 3C5/YAMAHA

Ignition coilModel/manufacturer 2JN/YAMAHAMinimum ignition spark gap 6.0 mm (0.24 in)Primary coil resistance 0.18–0.28 ΩSecondary coil resistance 6.32–9.48 kΩ

Spark plug capMaterial ResinResistance 10.0 kΩ

AC magnetoModel/manufacturer F5XT/YAMAHAStandard output 14.0 V, 190 W@5000 r/minStator coil resistance 0.688–1.032 Ω (White–white)Rectifier/regulator

Regulator type Semi conductor-short circuitModel/manufacturer SH629A-12/SHINDENGENNo load regulated voltage 14.1–14.9 VRectifier capacity 10.0 AWithstand voltage 200.0 V

BatteryModel YTZ7SVoltage, capacity 12 V, 6.0 AhSpecific gravity 1.310Manufacturer GS YUASATen hour rate amperage 0.60 A

HeadlightBulb type Halogen bulb

Bulb voltage, wattage × quantityHeadlight 12 V, 60 W/55.0 W × 1Tail/brake light 12 V, 8.0 W/27.0 W × 1Front turn signal/position light 12 V, 27 W/5.0 W × 2Rear turn signal light 12 V, 27.0 W × 2License plate light 12 V, 8.0 W × 1

Indicator lightNeutral indicator light LEDTurn signal indicator light LEDHigh beam indicator light LED


2-12

Electric starting systemSystem type Constant mesh

Starter motorModel/manufacturer 3C5/YAMAHAPower output 0.40 kWArmature coil resistance 0.0126–0.0154 ΩBrush overall length 10.0 mm (0.39 in)Limit 3.50 mm (0.14 in)Brush spring force 5.52–8.28 N (19.87–29.80 oz) (563–844 gf)Commutator diameter 22.0 mm (0.87 in)Limit 21.0 mm (0.83 in)Mica undercut (depth) 1.50 mm (0.06 in)

Starter relayModel/manufacturer 2768096-A/JIDECOAmperage 180.0 ACoil resistance 4.18–4.62 Ω

HornHorn type PlaneQuantity 1 pcsModel/manufacturer HF-12/NIKKOMaximum amperage 3.0 ACoil resistance 1.01–1.11 ΩPerformance 108–116 dB/2m

Turn signal relayRelay type Full transistorModel/manufacturer FE218BH/DENSOBuilt-in, self-canceling device NoTurn signal blinking frequency 75–95 cycles/min

Starting circuit cut-off relayModel/manufacturer ACM33211 M04/MATSUSHITACoil resistance 86.4–105.6 ΩCarburetor warmer resistance 4.7–9.5 W 20°C (68°F)

FusesMain fuse 20.0 ASpare fuse 20.0 A

TIGHTENING TORQUES

2-13

EAS20320

TIGHTENING TORQUES

EAS20330

GENERAL TIGHTENING TORQUE SPECIFICATIONSThis chart specifies tightening torques for stan-dard fasteners with a standard ISO thread pitch.Tightening torque specifications for special com-ponents or assemblies are provided for eachchapter of this manual. To avoid warpage, tight-en multi-fastener assemblies in a crisscross pat-tern and progressive stages until the specifiedtightening torque is reached. Unless otherwisespecified, tightening torque specifications re-quire clean, dry threads. Components should beat room temperature.

EAS20340

ENGINE TIGHTENING TORQUES

A. Distance between flats

B. Outside thread diameter

A (nut) B (bolt)General tightening torques

Nm m•kg ft•lb

10 mm 6 mm 6 0.6 4.3

12 mm 8 mm 15 1.5 11

14 mm 10 mm 30 3.0 22

17 mm 12 mm 55 5.5 40

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13.0 94

ItemThread size

Q’ty Tightening torque Remarks

Camshaft sprocket cover bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)

Timing chain tensioner bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)

Intake manifold bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)

Air induction system pipe M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)

Cylinder bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)

Clutch cover bolt M6 13 10 Nm (1.0 m•kg, 7.2 ft•lb)

Oil filter element drain bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)

Generator rotor cover bolt M6 9 10 Nm (1.0 m•kg, 7.2 ft•lb)

Speed sensor bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)

Crankcase bolt M6 12 10 Nm (1.0 m•kg, 7.2 ft•lb)

Drive sprocket cover bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)

Cylinder head bolt (226 mm) M8 4 22 Nm (2.2 m•kg, 16 ft•lb)

Cylinder head bolt (45 mm) M8 2 20 Nm (2.0 m•kg, 15 ft•lb)

Camshaft retainer bolt M6 1 8 Nm (0.8 m•kg, 5.8 ft•lb)

Tappet cover M55 2 18 Nm (1.8 m•kg, 13 ft•lb)

LT

TIGHTENING TORQUES

2-14

Breather plate bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)

Spark plug M12 1 18 Nm (1.8 m•kg, 13 ft•lb)

Exhaust pipe stud bolt M8 2 15 Nm (1.5 m•kg, 11 ft•lb)

Oil check bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)

Generator rotor bolt M10 1 60 Nm (6.0 m•kg, 43 ft•lb)

Balancer driven gear nut M12 1 55 Nm (5.5 m•kg, 40 ft•lb)lock

washer use

Locknut (valve clearance adjust-ing screw)

M6 2 14 Nm (1.4 m•kg, 10 ft•lb)

Camshaft sprocket bolt M10 1 60 Nm (6.0 m•kg, 43 ft•lb)

Timing chain tensioner cap bolt M6 1 8 Nm (0.8 m•kg, 5.8 ft•lb)

Timing chain guide (intake side) M6 2 8 Nm (0.8 m•kg, 5.8 ft•lb)

Oil filter element cover bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)

Oil delivery pipe bolt M10 1 20 Nm (2.0 m•kg, 15 ft•lb)

Oil delivery pipe bolt M8 1 17 Nm (1.7 m•kg, 12 ft•lb)

Oil pump cover screw M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)

Oil pump assembly bolt M6 3 6 Nm (0.6 m•kg, 4.3 ft•lb)

Air filter case bolt M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)

Air cut-off valve bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)

Exhaust pipe joint bolt M8 1 20 Nm (2.0 m•kg, 15 ft•lb)

Exhaust pipe nut M8 2 18 Nm (1.8 m•kg, 13 ft•lb)

Muffler bolt M8 2 42 Nm (4.2 m•kg, 30 ft•lb)

Stator assembly lead holder bolt M5 1 7 Nm (0.7 m•kg, 5.1 ft•lb)

Engine oil drain bolt M12 1 20 Nm (2.0 m•kg, 15 ft•lb)

Clutch cable holder bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)

Neutral switch lead holder bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)

Starter clutch idle gear cover bolt M6 3 8 Nm (0.8 m•kg, 5.8 ft•lb)

Bearing retainer M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)

Starter clutch bolt M8 3 30 Nm (30. m•kg, 22 ft•lb)

Primary drive gear nut M16 1 80 Nm (8.0 m•kg, 58 ft•lb)lock

washer use

ItemThread size


LT

LT

LT

LT

LT

LT

LT

TIGHTENING TORQUES

2-15

EAS20350

CHASSIS TIGHTENING TORQUES

Clutch boss nut M16 1 75 Nm (7.5 m•kg, 54 ft•lb)lock

washer use

Clutch spring bolt M6 5 8 Nm (0.8 m•kg, 5.8 ft•lb)

Lock nut (Push lever adjusting screw)

M6 1 8 Nm (0.8 m•kg, 5.8 ft•lb)

Push lever holding bolt M8 1 12 Nm (1.2 m•kg, 8.7 ft•lb)

Drive sprocket nut M18 1 110 Nm (11.0 m•kg, 80 ft\•lb)lock

washer use

Stopper lever bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)

Neutral switch M10 1 20 Nm (2.0 m•kg, 15 ft•lb)

Starter motor bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)

Pickup coil bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)

Stator assembly bolt M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)

ItemThread size


LT

LT

LT

ItemThread size


Engine mounting nut M10 3 60 Nm (6.0 m•kg, 43 ft•lb)

Engine bracket nut M8 2 44 Nm (4.4 m•kg, 32 ft•lb)

Down tube nut M10 5 60 Nm (6.0 m•kg, 43 ft•lb)

Drive chain tensioner bolt M8 1 23 Nm (2.3 m•kg, 17 ft•lb)

Mudguard bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)

Front fender bolt M6 4 7 Nm (0.7 m•kg, 5.1 ft•lb)

Grab bar bolt M8 4 23 Nm (2.3 m•kg, 17 ft•lb)

Rear side cover bolt M6 2 9 Nm (0.9 m•kg, 6.5 ft•lb)

Tool box bolt M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)

Horn bracket bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)

Battery/Electrical box bolt M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)

Rectifier/regulator bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)

Starter motor lead bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)

Ignition coil bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)

Pivot shaft nut M12 1 80 Nm (8.0 m•kg, 58 ft•lb)

Rear shock absorber assembly upper nut

M12 2 50 Nm (5.0 m•kg, 36 ft•lb)

TIGHTENING TORQUES

2-16

Relay arm nut (frame side) M12 2 50 Nm (5.0 m•kg, 36 ft•lb)

Steering stem nut M22 1 110 Nm (11.0 m•kg, 80 ft•lb)

Lower ring nut M22 1 –See

NOTE

Fuel tank bolt M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)

Brake hose union bolt M10 3 30 Nm (3.0 m•kg, 22 ft•lb)

Brake hose holding bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)

Front brake hose holding bolt (holder and lower bracket)

M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)

Handlebar holder bolt M8 4 23 Nm (2.3 m•kg, 17 ft•lb)

Sidestand nut M10 1 44 Nm (4.0 m•kg, 32 ft•lb)

Brake pedal bolt M10 1 30 Nm (30. m•kg, 22 ft•lb)

Rear brake caliper cover M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)

Rear brake master cylinder bolt M6 2 13 Nm (1.3 m•kg, 9.4 ft•lb)

Passenger footrest bracket bolt M8 4 23 Nm (2.3 m•kg, 17 ft•lb)

Upper bracket pinch bolt M8 4 23 Nm (2.3 m•kg, 17 ft•lb)

Meter stay bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)

Headlight unit bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)

Rear shock absorber assembly lower nut

M10 2 40 Nm (4.0 m•kg, 29 ft•lb)

Connecting arm bolt (relay arm side)

M12 1 59 Nm (5.9 m•kg, 43 ft•lb)

Connecting arm bolt (swingarm side)

M12 1 59 Nm (5.9 m•kg, 43 ft•lb)

Rear drive chain guide bolt M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)

Lower bracket pinch bolt M8 4 23 Nm (2.3 m•kg, 17 ft•lb)

Front fork cap bolt M30 2 23 Nm (2.3 m•kg, 17 ft•lb)

Damper rod bolt M8 2 18 Nm (1.8 m•kg, 13 ft•lb)

Front wheel axle nut M14 1 85 Nm (8.5 m•kg, 62 ft•lb)

Front brake disc bolt M6 6 10 Nm (1.0 m•kg, 7.2 ft•lb)

Front brake caliper bracket bolt M10 2 40 Nm (4.0 m•kg, 29 ft•lb)

Front brake caliper support bolt M10 2 32 Nm (3.2 m•kg, 23 ft•lb)

Bleed screw M7 2 6 Nm (0.6 m•kg, 4.3 ft•lb)

Rear wheel axle nut M14 1 85 Nm (8.5 m•kg, 62 ft•lb)

Rear wheel sprocket self-locking nut

M8 1 33 Nm (3.3 m•kg, 24 ft•lb)

ItemThread size


LT

LT

LT

TIGHTENING TORQUES

2-17

NOTE:

Tighten the lower ring nut with the specified torque (38 Nm (3.8 m•kg, 28 ft•lb)). Check the front fork leg operates smoothly by turning it to the right and left. Loosen the lower ring nut completely and retighten it with the specified torque (4 Nm (0.4 m•kg, 2.9

ft•lb)).

Rear brake disc bolt M8 3 28 Nm (2.8 m•kg, 21 ft•lb)

Front brake master cylinder holder bolt

M6 2 7 Nm (0.7 m•kg, 5.1 ft•lb)

Front brake lever nut M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)

Rear brake hose joint (caliper side)

M10 1 26 Nm (2.6 m•kg, 19 ft•lb)

Rear brake hose joint (hose side) M10 1 14 Nm (1.4 m•kg, 10 ft•lb)

Rear brake pad support bolt M10 2 17 Nm (1.7 m•kg, 12 ft•lb)

ItemThread size


LT

LUBRICATION POINTS AND LUBRICANT TYPES

2-18

EAS20360


EAS20370

ENGINE

Lubrication point Lubricant

Oil seal lips

All O-rings

All bearing retainers

Seat surface of cylinder head bolt (226 mm)

Threaded portion of cylinder head bolt (226 mm)

Cylinder inner surface

Crankshaft pin surface

Thrust end surface of connecting rod big end

Piston pin surface

Piston surface

Buffer boss surface

Valve stem (intake/exhaust)

Valve stem end (intake/exhaust)

Rocker arm shaft surface (intake/exhaust)

Camshaft profile

Rocker arm inner surface (intake/exhaust)

Inside of oil pump assembly

Oil pump gasket

Starter clutch idle gear 1

Starter clutch idle gear 2

Starter clutch gear

Clutch push rod surface, and surface end

Adjusting screw surface, and surface end (push lever)

Primary driven gear (clutch housing)

Push lever shaft surface

LS

LS

E

E

M

E

E

E

E

E

E

M

M

E

M

M

E

LS

E

E

E

LS

LS

E

E


2-19

EAS20380

CHASSIS

Ball surface (clutch push rod)

Main axle assembly

Drive axle assembly

Shift fork guide bar

Shift drum assembly

Shift shaft assembly

Shift pedal (bolt mount inner surface)

Crankcase mating surfaceYamaha bond No. 1215 (Three Bond

No. 1215®)

Threaded portion of starter motor boltYamaha bond No. 1215 (Three Bond

No. 1215®)


LS

M

M

E

E

E

LS


Upper bearings and oil seal lip (steering head)

Lower bearings and oil seal lip (steering head)

Front wheel oil seal lip (left/right)

Rear wheel oil seal lip (left/right)

Brake pedal bolt shaft

Throttle grip and throttle cable end

Throttle cable housing inner surface

Brake lever bolt shaft

Brake lever and front brake master cylinder moving parts

Adjusting screw end (brake lever)

Rear brake master cylinder pushrod (boot mount groove)

Brake caliper piston seal

Brake caliper support bolt shaft

Brake pad support bolt shaft

LS

LS

LS

LS

LS

LS

LS

S

S

S

S

S

S

S


2-20

Clutch lever cable mount

Clutch lever bolt shaft

Clutch lever moving parts

Pivot shaft surface

Swing arm bushing, spacer, and oil seal lip

Relay arm bushing, spacer, and oil seal lip

Relay arm bolt shaft (on the frame and connecting arm)

Relay arm bolt shaft

Connecting arm bolt shaft

Lower bolt shaft of rear shock absorber assembly

Rear wheel axle surface

Sidestand switch end and contact

Frame and sidestand link moving parts

Sidestand bolt collar surface

Drive chain roller collar surface

Tandem footrest moving parts


LS

LS

LS

M

M

M

M

M

M

M

LS

LS

LS

LS

LS

LS

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-21

EAS20390


EAS20400

ENGINE OIL LUBRICATION CHART

6 7

8

2

4

10

1

5

11

9

1

2

3

4

5


2-22

1. Camshaft

2. Oil filter element

3. Oil level check window

4. Oil pump assembly

5. Oil strainer

6. Drive axle

7. Main axle

8. Plunger pin

9. Crankshaft

10. Cylinder head

11. Oil pan


2-23

EAS20410

LUBRICATION DIAGRAMS

8

2

6

4

1 2

3

7

5


2-24

1. Crankshaft

2. Oil pump assembly

3. Oil strainer

4. Camshaft

5. Push lever shaft

6. Drive axle

7. Main axle

8. Oil filter element

CABLE ROUTING

2-25

EAS20430

CABLE ROUTING

B

B

A

A

F

F

E E

C

C

G

D

A B

C

D

FE

G

H

L

J

K

M

N

O

P

RS

QT

U

V

W

X

YZ

1

33

3

4

5

6

7

8

8

911

10

10

12

13

22

21

13

15

13

14

20

16

16

17

1819

19

AC

AD

AF

AE

AGAH

AI

AMAN AN

AJ

ABAA

I

2

AF

AK

AL

CABLE ROUTING

2-26

1. Headlight relay (lead having gray tape)

2. Starting circuit cut-off relay

3. Carburetor warmer lead

4. Throttle pulley

5. Throttle cable (decelerator cable )

6. Throttle cable (accelerator cable)

7. Horn lead

8. Starter motor lead

9. Diode1

10. Negative battery lead

11. Diode3

12. Rear brake light switch

13. Rear brake light switch lead

14. Starter relay lead

15. Turn signal relay

16. Wire harness

17. Rear turn signal light leads (left/right)

18. Positive battery lead

19. Clutch cable

20. Toolbox

21. Clamp

22. Battery box

A. 35 mm (1.38 in)

B. Clamp the wire harness using plastic locking tie. Face the cable tie end upwards, and cut off the excess end of the tie. When clamping, locate the connection of relay leads below the seat rails, but at the side of the fuel tank bracket (rear fuel tank bolt mount).

C. 30 mm (1.18 in)

D. Route the starter motor cable outside each lead.

E. Clamp the wire harness using a plastic locking tie. Face the plastic locking tie end upwards, and cut off the excess end of the tie.

F. 30 mm (1.18 in)

G. Clamp the wire harness, clutch cable, and car-buretor warmer lead using plastic locking tie. Enter the cable tie in the frame opening. Face the cable tie end upwards, and cut off the excess end of the tie.

H. Secure the right handlebar switch lead, front brake light switch lead, right front turn signal light lead, and meter assembly leads using clamp. Face the clamp opening downwards.

I. Route the throttle cable inside of each lead.

J. Route each lead without slack.

K. Route the leads from the cutout of front right sidecover to inside of the sidecover.

L. Pass the throttle cable through the guide.

M. Each lead should not be exposed to the outside of the right front sidecover.

N. Pass the horn lead inside of the throttle cable and secure it to the T-stud of the frame.

O. Route the throttle cable above the cylinder head breather hose.

P. Clamp the clutch cable, starter motor lead, and carburetor warmer lead using plastic locking tie. Face the cable tie end outwards and cut off the excess end of the tie. Take care not to make the latchet face inwards towards the vehicle.

Q. Install diode 1 in the battery/electric parts box.

R. Pass the negative battery lead behind the wire harness. Also, pass the battery lead from the battery/electric parts box through the inside of the vehicle.

S. Gray tape (headlight relay lead)

T. Install diode 3 in front of the headlight relay.

U. Clamp the rear brake light switch lead using clamps. Face the clamp opening inwards .

V. Pass the rear brake light switch lead along the frame, and install the rear brake light switch.

W. Secure the rear brake light switch lead to the frame using clamps.

X. Clamp the wire harness, tail/brake light leads, rear turn signal light leads (left and right), and rear brake light switch lead using plastic locking tie. Face the end of the locking tie upward and cut off the excess end of the tie.

Y. Route leads between the frames and inside of the vehicle as shown in the illustration.

Z. Pass a plastic locking tie through the front side hole of the frame bracket and then clamp the rear turn signal light leads (left and right) and tail/brake light leads. Face the end of the locking tie upward and cut off the excess end of the locking tie.

AA. Route the rear turn signal light leads (left and right), tail/brake light leads, and rear brake light switch lead under the battery band.

AB. Route the negative battery lead outside other leads.

AC. Do not route the rear turn signal light leads (left and right) above the top panel of the battery/electric parts box.

AD. Clamp the starter relay lead, headlight relay lead, starting circuit cut-off relay lead, diode1 lead, and diode3 lead using plastic locking tie. Insert the latchet and the excess tail of the cable tie into the inside.

AE. Pass the rear brake light switch lead between the battery/electric parts box and the positive battery lead.

AF. Less than 2 mm (0.08 in)

AG. Route the carburetor warmer lead outside the clutch cable and starter motor lead.

AH. Route the carburetor warmer lead outside the wire harness.

AI. Pass the left handlebar switch lead, clutch switch lead, main switch lead, and front left turn signal light lead through the boot. Push and hold the boot onto the coupler end.

AJ. Pass the horn lead, meter assembly lead, right handlebar switch lead, front brake light switch lead, and front right turn signal light lead through the boot. Push and hold the boot onto the coupler end.

AK. The boot should be located under the toolbox end.

AL. Clamp the rear brake switch lead, taillight lead and two negative battery leads using plastic locking tie. The cable tie end should face down-ward. Do not clamp the couplers.

AM. Pass a plastic locking tie through the hole of frame gasset and then clamp the rear turn sig-nal light leads and tail light lead. Face the end of the locking tie upward and cut off the excess end of the locking tie.

AN. The relay with the diode is front side and the relay with gray tape is rear side.

CABLE ROUTING

2-27

DB

A

E

C

F

A

B

C

D

E F

G

G

H

H

I

J

K

L

M

N

O

P

QQ

R

S

V

T

U

1

2 3

4

5

6 P 6

6

7

7

8

9

11

10

121314151617

18

19

20

22

21

V

G

O

CABLE ROUTING

2-28

1. Clutch cable

2. Starter cable

3. Air induction system hose (from air filter case to air cut-off valve)

4. Cylinder head breather hose

5. Sidestand switch lead

6. Speed sensor lead

7. Neutral switch lead

8. Stator assembly lead

9. Main switch lead

10. Meter assembly leads

11. Front brake hose

12. Throttle cable (decelerator cable)


14. Right handlebar switch lead

15. Front brake light switch lead

16. Left handlebar switch lead

17. Clutch switch lead


19. Speed sensor

20. Rear turn signal light

21. Carburetor fuel drain hose

22. Rear turn signal light bracket

A. Each lead should not be exposed to the outside of the front left sidecover.

B. Secure the left handlebar switch lead, clutch switch lead, front left turn signal light lead, and main switch lead using clamp. Face the clamp opening downwards.

C. Pass the clutch cable through the guide.

D. Enter each lead from the cutout of front left sidecover and run inside of the sidecover. Install each lead above the clutch cable without slack.

E. Clamp the starter cable using plastic locking tie and cut off the excess end of the tie. Face the end of the tie downwards.

F. Pass the starter cable through the square shape of air cut-off valve bracket, and route out-side the air induction system hose (from air filtercase to air cut-off valve) and cylinder head breather hose.

G. Secure the ignition coil lead, stator assembly lead, sidestand switch lead, neutral switch lead, and speed sensor lead using clamp. Face the clamp opening upward.

H. Secure the sidestand switch lead to the frame using clamps.

I. Secure the neutral switch lead and speed sen-sor lead using clamp. Face the clamp opening backward.

J. Secure the stator assembly lead using clamps. The clamp opening should face downwards away from the vehicle.

K. Secure the wire harness boot onto the guide.

L. Route the clutch cable above the cylinder head breather hose.

M. Route the clutch cable at the rear of the guide.

N. Pass the ignition coil lead, stator assembly lead, sidestand switch lead, neutral switch lead, and speed sensor lead through the boot. Insert all couplers into the boot.

O. Secure two carburetor air vent hoses, carbure-tor fuel drain hose, and negative battery lead using clamp. Face the clamp holders on the left of the vehicle.

P. Pass the speed sensor lead between each hose and the crankcase.

Q. Secure two carburetor air vent hoses, carbure-tor fuel drain hose, and neutral switch lead using clamp.

R. Secure the neutral switch lead using clamp.

S. Pass the rear turn signal light leads (left and right) through the opening of rear turn signal light bracket, and secure the leads using plastic locking tie. Face the cable tie end inward, and cut off the excess end of the tie.

T. Route the carburetor fuel drain hose through the guide.

U. Route the carburetor fuel drain hose through the rear of frame cross tube as shown in the illustration.(Except for California)

V. Using plastic locking tie, secure the neutral switch lead and speed sensor lead onto the clamp as shown in the illustration.

CABLE ROUTING

2-29

L

J

M

N

3

4

5

6

16

N

M

A

A

C

D

E

FF

G

H

J

I

K

1 2 3 4

56

7

8

9

10

11

12

13

14

1516

17

B

B

D C

3

4 5615

15

16

F

F

E

E

1

B

CABLE ROUTING

2-30

1. Clutch cable

2. Front brake hose

3. Front brake light switch lead

4. Right handlebar switch lead




8. Starter motor lead

9. Rear brake light switch lead


11. Tail/brake light lead/

12. Rear turn signal light leads

13. Thermo switch

14. Rectifier/regulator lead

15. Clutch switch lead

16. Left handlebar switch lead

17. Rectifier/regulator

A. Enter two wire harnesses from the opening of frame cross tube, pass them through the inside of the vehicle, and secure them using plastic locking tie. Face the cable tie end backwards away from the frame cross tube, and cut off the excess end of the tie.

B. Less than 2 mm (0.08 in)

C. Clamp rear turn signal light leads (left and right) and tail/brake light leads using plastic locking tie. Face the cable tie end outwards and cut off the excess end of the tie.

D. Install each lead under the frame without slack.

E. Secure the rear turn signal light leads (left and right) and tail/brake light leads with clamp. Face the clamp opening upwards.

F. Secure the rear left turn signal light lead to the end of rear fender bracket (soldered to the frame) using plastic locking ties. Face the cable tie end backward, and cut off the excess end of the tie if longer than 3 mm (0.12 in).

G. Install the left rear turn signal light lead under the frame without slack.

H. Secure the thermo switch lead, rectifier/regula-tor lead, and rectifier/regulator ground lead using clamps.

I. Secure the wire harness to the T-stud of the frame.

J. Clamp the clutch cable, throttle cable (accelera-tor cable), and throttle cable (decelerator cable) using plastic locking tie. Face the tied end inward, and cut off the excess end of the tie.

K. Route the clutch cable between the throttle cable (accelerator cable) and the throttle cable (decelerator cable).

L. Install the rectifier/regulator lead in horizontal to the vehicle.

M. Clamp the plastic locking tie onto the bends of handle as shown in the illustration.

N. Face the plastic locking tie end downwards.

CABLE ROUTING

2-31

A

D

C

I

H

G

1

2

3

4

5

6

8

E

L

K

M

J

B

A A7

F

CABLE ROUTING

2-32



3. Meter assembly leads

4. Clutch cable

5. Left front turn signal light lead

6. Main switch lead

7. Right front turn signal light lead

8. Front brake hose

A. Route the meter assembly leads, and main switch leads from the top of the guide to the backward of vehicle.

B. To the meter assembly.

C. Install the left front turn signal light lead to the cap.

D. Route the clutch cable and front left turn signal light lead at the rear of the guide. However, route the main switch leads at the front of the guide.

E. Install the 3-pin coupler for the meter assembly and left handlebar switch as shown in the illus-tration.

F. To the headlight.

G. Band the meter assembly leads, handlebar switch leads (left and right), front brake light switch lead, front turn signal light leads (left and right), clutch switch lead, and main switch leads with plastic locking tie. The plastic locking tie should position bottom end of the main switch, and face tail forward.

H. Bottom end of the main switch

I. Install the front right turn signal light lead to the cap.

J. Never clamp the throttle cable (accelerator cable) and the throttle cable (decelerator cable) using plastic locking tie.

K. Position the 3-pin coupler for the meter assem-bly and left handlebar switch at the front of vehi-cle.

L. Forward of the vehicle.

M. Face the latchet side of the band outward.

CABLE ROUTING

2-33

C

E

G

H

1

3

A

A

B

D

F

E

G

L

J

K

M

N

3

4 I

2

G

2

B

C

D

CABLE ROUTING

2-34

1. Fuel tank

2. Roll over valve

3. Canister

4. Canister breather hose

A. Face the end of clip toward the vehicle.

B. Install the hose to fuel tank by facing the white paint mark left side of the vehicle.

C. Pass through the hose in the space of the tool box.

D. Install the hose to the roll over valve and canis-ter.

E. Install the hose to the carburetor and canister.

F. Pass through the hose to the guide.

G. The clip may be installed, which ever direction end of the clip.

H. Pass through the canister breather hose to the guide.

I. Install the end of the canister breather hose to inside of the frame by facing the cut end of the hose downward.

J. Install the hose to the carburetor by facing the white paint mark left side of the vehicle.

K. Pass through the hose onto the guide.

L. Face the end of clip right side of the vehicle.

M. Face the end of clip downward of the vehicle.

N. Fasten the hose and cylinder head breather hose by using the clamp.

CABLE ROUTING

2-35

1

2

3

4

5

6

7

8

9

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE...........................................................................3-1INTRODUCTION......................................................................................3-1Periodic maintenance chart for the emission control system ...................3-1General maintenance and lubrication chart..............................................3-2

ENGINE ..........................................................................................................3-5ADJUSTING THE VALVE CLEARANCE .................................................3-5ADJUSTING THE ENGINE IDLING SPEED............................................3-6ADJUSTING THE THROTTLE CABLE FREE PLAY ...............................3-7CHECKING THE SPARK PLUG ..............................................................3-8CHECKING THE IGNITION TIMING........................................................3-8MEASURING THE COMPRESSION PRESSURE...................................3-9CHECKING THE ENGINE OIL LEVEL ....................................................3-10CHANGING THE ENGINE OIL ................................................................3-11ADJUSTING THE CLUTCH CABLE FREE PLAY....................................3-12REPLACING THE AIR FILTER ELEMENT..............................................3-13CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD ......3-14CHECKING THE FUEL LINE...................................................................3-14CHECKING THE CYLINDER HEAD BREATHER HOSE ........................3-14CHECKING THE EXHAUST SYSTEM ....................................................3-14

CHASSIS........................................................................................................3-16ADJUSTING THE FRONT DISC BRAKE.................................................3-16ADJUSTING THE REAR DISC BRAKE...................................................3-16CHECKING THE BRAKE FLUID LEVEL .................................................3-17CHECKING THE FRONT BRAKE PADS.................................................3-17CHECKING THE REAR BRAKE PADS ...................................................3-18CHECKING THE FRONT BRAKE HOSE ................................................3-18CHECKING THE REAR BRAKE HOSE...................................................3-18ADJUSTING THE REAR BRAKE LIGHT SWITCH..................................3-18BLEEDING THE HYDRAULIC BRAKE SYSTEM ....................................3-19ADJUSTING THE DRIVE CHAIN SLACK................................................3-20LUBRICATING THE DRIVE CHAIN.........................................................3-20CHECKING AND ADJUSTING THE STEERING HEAD..........................3-21CHECKING THE FRONT FORK..............................................................3-22ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY...................3-22CHECKING THE TIRES...........................................................................3-23CHECKING THE WHEELS......................................................................3-24CHECKING AND TIGHTENING THE SPOKES.......................................3-25CHECKING AND LUBRICATING THE CABLES .....................................3-25LUBRICATING THE LEVERS..................................................................3-25LUBRICATING THE PEDAL ....................................................................3-25LUBRICATING THE SIDESTAND ...........................................................3-25LUBRICATING THE REAR SUSPENSION .............................................3-25

ELECTRICAL SYSTEM .................................................................................3-26CHECKING AND CHARGING THE BATTERY........................................3-26CHECKING THE FUSES .........................................................................3-26REPLACING THE HEADLIGHT BULB ....................................................3-26ADJUSTING THE HEADLIGHT BEAM....................................................3-26

PERIODIC MAINTENANCE

3-1

EAS20450


EAS20460

INTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments. If

followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long-

er service life and reduce the need for costly overhaul work. This information applies to vehicles already

in service as well as to new vehicles that are being prepared for sale. All service technicians should be

familiar with this entire chapter.

NOTE:

If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform

it for you.

WARNING

EWA10340

Modifications not approved by Yamaha may cause loss of performance, excessive emissions,

and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.

EAS17580

Periodic maintenance chart for the emission control system

No

.ITEM ROUTINE

INITIAL ODOMETER READINGS

600 mi

(1000 km)

or

1 month

4000 mi

(6000 km)

or

6 months

7000 mi

(11000

km)

or

12 months

10000 mi

(16000

km)

or

18 months

13000 mi

(21000

km)

or

24 months

16000 mi

(26000

km)

or

30 months

1 * Fuel hose

Check fuel hoses for

cracks or damage.

Replace if necessary.

√ √ √ √ √

2 Spark plug

Check condition.

Adjust gap and clean.

Replace at 7000 mi (11000

km) or 12 months and

thereafter every 6000 mi

(10000 km) or 12 months.

√ Replace. √ Replace. √

3 Spark arrester Clean. √ √ √ √ √

4 * Valve clearance

Check and adjust valve

clearance when engine is

cold.

√ √ √ √ √ √

5 *Crankcase

breather system

Check breather hose for

cracks or damage.


√ √ √ √ √

6 * Idle speed Check and adjust engine

idle speed.√ √ √ √ √

7 * Exhaust system

Check for leakage.

Tighten if necessary.

Replace gasket(s) if nec-

essary.

√ √ √ √ √

8 *

Evaporative emis-

sion control sys-

tem (For

California only)

Check control system for

damage.

Replace if necessary.√ √


3-2

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

EAS32164

General maintenance and lubrication chart

9 *Air induction sys-

tem

Check the air cut-off valve,

reed valve, and hose for

damage.

Replace any damaged

parts.

√ √

No

.ITEM ROUTINE


600 mi

(1000 km)

or

1 month

4000 mi

(6000 km)

or

6 months

7000 mi

(11000

km)

or

12 months

10000 mi

(16000

km)

or

18 months

13000 mi

(21000

km)

or

24 months

16000 mi

(26000

km)

or

30 months

1 * Air filter element

Check condition and for

damage.


√ √ √ Replace. √

Replace. Replace at 13000 mi (21000 km) and there after every 12000 mi (20000 km).

2 * Clutch Check operation.

Adjust or replace cable.√ √ √ √ √ √

3 * Front brake

Check operation, fluid

level, and for fluid leakage.

Replace brake pads if nec-

essary.

√ √ √ √ √ √

4 * Rear brake

Check operation, fluid

level, and for fluid leakage.

Replace brake pads if nec-

essary.

√ √ √ √ √ √

5 * Brake hose

Check for cracks or dam-

age.√ √ √ √ √

Replace. Every 4 years

6 * Wheels

Check runout, spoke tight-

ness and for damage.

Tighten spokes if neces-

sary.

√ √ √ √ √

7 * Tires

Check tread depth and for

damage.


Check air pressure.

Correct if necessary.

√ √ √ √ √

8 * Wheel bearings

Check bearings for smooth

operation.


√ √ √ √ √

9 *Swingarm pivot

bushes

Check bush assemblies for

looseness.

Lubricate with lith-

ium-soap-based grease.

√ √ √ √ √

No

.ITEM ROUTINE


600 mi

(1000 km)

or

1 month

4000 mi

(6000 km)

or

6 months

7000 mi

(11000

km)

or

12 months

10000 mi

(16000

km)

or

18 months

13000 mi

(21000

km)

or

24 months

16000 mi

(26000

km)

or

30 months


3-3

10 Drive chain

Check chain slack, align-

ment and condition.

Adjust and lubricate chain

with a special O-ring chain

lubricant thoroughly.

Every 300 mi (500 km) and after washing the motorcycle or riding in the rain

11 * Steering bearings

Check bearing assemblies

for looseness.

Moderately repack with

lithium-soap-based

grease.

√ √ √ √ Repack. √

12 * Chassis fasteners

Check all chassis fitting

and fasteners.

Correct if necessary.

√ √ √ √ √

13Brake lever pivot

shaft

Apply silicone grease

lightly.√ √ √ √ √

14Brake pedal pivot

shaft

Apply lithium-soap-based

grease lightly.√ √ √ √ √

15Clutch lever pivot

shaft



16Shift pedal pivot

shaft



17 Sidestand pivot

Check operation.


grease lightly.

√ √ √ √ √

18 * Sidestand switch Check operation and

replace if necessary.√ √ √ √ √ √

19 * Front fork

Check operation and for oil

leakage.


√ √ √ √ √

20 *Shock absorber

assembly

Check operation and for oil

leakage.


√ √ √ √ √

21 *Rear suspension

link pivots

Check operation.

Correct if necessary.√ √

22 Engine oil Change (warm engine

before draining).√ √ √ √ √ √

23Engine oil filter

element

Replace.√ √ √

24 *Front and rear

brake switches

Check operation.√ √ √ √ √ √

25 * Control cables

Apply Yamaha chain and

cable lube or engine oil

SAE 10W-30 thoroughly.

√ √ √ √ √ √

26 *

Throttle grip

housing and

cable

Check operation and free

play.

Adjust the throttle cable

free play if necessary.

Lubricate the throttle grip

housing and cable.

√ √ √ √ √

No

.ITEM ROUTINE


600 mi

(1000 km)

or

1 month

4000 mi

(6000 km)

or

6 months

7000 mi

(11000

km)

or

12 months

10000 mi

(16000

km)

or

18 months

13000 mi

(21000

km)

or

24 months

16000 mi

(26000

km)

or

30 months


3-4

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

NOTE:

From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi(11000 km) or 12 months.

NOTE:

Air filter This model’s air filter is equipped with a disposable oil-coated paper element, which must not be

cleaned with compressed air to avoid damaging it. The air filter element needs to be replaced more frequently when riding in unusually wet or dusty

areas. Hydraulic brake service

After disassembling the brake master cylinders and calipers, always change the fluid. Regularlycheck the brake fluid levels and fill the reservoirs as required.

Every two years replace the internal components of the brake master cylinders and calipers, andchange the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.

27 *Lights, signals

and switches

Check operation.

Adjust headlight beam.√ √ √ √ √ √

No

.ITEM ROUTINE


600 mi

(1000 km)

or

1 month

4000 mi

(6000 km)

or

6 months

7000 mi

(11000

km)

or

12 months

10000 mi

(16000

km)

or

18 months

13000 mi

(21000

km)

or

24 months

16000 mi

(26000

km)

or

30 months

ENGINE

3-5

EAS20471

ENGINE

EAS20520

ADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.NOTE:

Valve clearance adjustment should be madeon a cold engine, at room temperature.

When the valve clearance is to be measured oradjusted, the piston must be at top dead center(TDC) on the compression stroke.

1. Remove: Fuel tank

Refer to “FUEL TANK” on page 6-1.2. Remove:

Intake tappet cover “1” Exhaust tappet cover “2” Camshaft sprocket cover “3”

3. Remove: Spark plug cap Spark plug

4. Remove: Timing mark accessing screw “1” Crankshaft end cover “2”

5. Measure: Valve clearance

Out of specification → Adjust.

a. Turn the crankshaft counterclockwise.b. When the piston is in the compression stroke,

align camshaft sprocket mark “a” with cylin-der head mark “b”. This is the Top Dead Cen-ter (TDC).

c. Make sure that generator rotor mark “c”aligns with generator rotor cover mark “d”.

d. Measure the valve clearance using specialthickness gauge “1”.Out of specification → Adjust.

1

3

2

Valve clearance (cold)Intake

0.05–0.10 mm (0.0020–0.0039 in)Exhaust

0.10–0.15 mm (0.0039–0.0059 in)

Special thickness gauge90890-01399

1

ENGINE

3-6

6. Adjust: Valve clearance

a. Loosen the locknut “1”b. Insert special thickness gauge “2” between

the adjusting screw and the valve stem end.c. Using tappet adjusting tool “3”, turn the ad-

justing screw “4” in direction “a” or “b” to ad-just the valve clearance.

Hold the adjusting screw to prevent it frommoving and tighten the locknut to specifica-tion.

d. Measure the valve clearance again.e. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust-ment steps until the specified clearance isobtained.

7. Install: O-ring Crankshaft end cover O-ring Timing mark accessing screw

8. Install: Spark plug Spark plug cap

9. Install: O-ring Camshaft sprocket cover O-ring Exhaust tappet cover O-ring Intake tappet cover

10.Install: Fuel tank

Refer to “FUEL TANK” on page 6-1.

EAS20610

ADJUSTING THE ENGINE IDLING SPEEDNOTE:

Before adjusting the engine idling speed, the airfilter element should be clean, and the engineshould have adequate compression.

1. Install: Pocket tester (temperature probe) “1”

(To oil drain bolt) Digital tachometer

Direction “a”Increases the valve clearance.Direction “b”Decreases the valve clearance.

Tappet adjusting tool90890-01311

Six piece tappet setYM-A5970

Lock nut (valve clearance adjust-ing screw)

14 Nm (1.4 m•kg, 10 ft•lb)

1

4

3

2

a

b

TR..

New

New

Spark plug18 Nm (1.8 m•kg, 13 ft•lb)

Camshaft sprocket cover bolt10 Nm (1.0 m•kg, 7.2 ft•lb)

Exhaust tappet cover18 Nm (1.8 m•kg, 13 ft•lb)

Intake tappet cover18 Nm (1.8 m•kg, 13 ft•lb)



TR..

New

New

New

TR..

1

ENGINE

3-7

2. Start the engine and let it warm up until itreaches specified oil temperature.

3. Check: Engine idling speed


4. Adjust: Engine idling speed

a. Adjust the engine idling speed by turning thethrottle stop screw “1” in direction “a” or “b”.

5. Adjust: Throttle cable play

Refer to “ADJUSTING THE THROTTLE CA-BLE FREE PLAY” on page 3-9.

EAS20640

ADJUSTING THE THROTTLE CABLE FREE PLAYNOTE:

Before adjusting the throttle cable free play, theengine idling speed should be adjusted properly.

1. Check: Throttle cable play “a”


2. Adjust: Throttle cable free play

Carburetor sidea. Loosen locknut “1” of the pulling (accelerat-

ing) throttle cable.b. Adjust dimension “a” to approximately 5 mm

by turning the adjusting nut “2” as shown.c. Tighten the locknut “1”.

Oil temperature95.0–105.0 °C (203.00–221.00 °F)

Engine idling speed1300–1500 r/min

Direction “a”Increases the engine idling speed.Direction “b”Decreases the engine idling speed.

1ab

Throttle cable free play3.0–5.0 mm (0.12–0.20 in)


a

a

2

1

ENGINE

3-8

Handlebar sidea. Loosen the locknut “1”.b. Adjust the play of throttle cable by turning the

adjusting nut “2” in direction “a” or “b”.

c. Tighten the locknut.

WARNING

EWA12920

After adjusting the throttle cable free play,start the engine and turn the handlebars tothe right and to the left to ensure that thisdoes not cause the engine idling speed tochange.

EAS20690

CHECKING THE SPARK PLUG1. Disconnect:

Spark plug cap2. Remove:

Spark plug

CAUTION:

ECA13330

Before removing the spark plug, blow awayany dirt accumulated in the spark plug wellwith compressed air to prevent it from fallinginto the cylinder.

3. Check: Spark plug type

Incorrect → Change.

4. Check: Electrode “1”

Damage/wear → Replace the spark plug. Insulator “2”

Abnormal color → Replace the spark plug.Normal color is medium-to-light tan.

5. Clean: Spark plug

(with a spark plug cleaner or wire brush)6. Measure:

Spark plug gap “a”(with a wire thickness gauge)Out of specification → Regap.

7. Install: Spark plug

NOTE:

Before installing the spark plug, clean the sparkplug and gasket surface.

8. Connect: Spark plug cap

EAS20700

CHECKING THE IGNITION TIMINGNOTE:

Before checking the ignition timing, check thewiring connections of the entire ignition system.Make sure all connections are tight and free ofcorrosion.

1. Remove: Timing mark accessing screw “1”

Direction “a”Increases the throttle cable play.Direction “b”Decreases the throttle cable play.

Manufacturer/modelNGK/DR7EA

1

a

2

b Spark plug gap0.6–0.7 mm (0.024–0.028 in)

Spark plug18 Nm (1.8 m•kg, 13 ft•lb)T

R..

ENGINE

3-9

2. Connect: Timing light “1” Digital tachometer

3. Check: Ignition timing

a. Start the engine, warm it up to the specifiedoil temperature, then adjust to the standardidling speed.

b. Check the firing range as shown.Out of the firing range → Check the ignitionsystem

NOTE:

The ignition timing is not adjustable.

4. Remove: Digital tachometer Timing light

5. Install: Timing mark accessing screw

EAS20710

MEASURING THE COMPRESSION PRESSUREThe following procedure applies to all of the cyl-inders.NOTE:

Insufficient compression pressure will result in aloss of performance.

1. Measure: Valve clearance

Out of specification → Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE” on page 3-5.

2. Start the engine, warm it up for several min-utes, and then turn it off.

3. Disconnect: Spark plug cap

4. Remove: Spark plug

CAUTION:

ECA13340

Before removing the spark plugs, use com-pressed air to blow away any dirt accumulat-ed in the spark plug wells to prevent it fromfalling into the cylinders.

5. Install: Compression gauge “1”

Timing light90890-03141

Inductive clamp timing lightYU-03141



1

ENGINE

3-10

6. Measure: Compression pressure

Out of specification → Refer to steps (c) and(d).

a. Set the main switch to “ON”.b. With the throttle wide open, crank the engine

until the reading on the compression gaugestabilizes.

WARNING

EWA12960

To prevent sparking, ground the spark pluglead before cranking the engine.

NOTE:

Make use the battery is fully charged when tak-ing measurements.

Make sure there is no compression leakagefrom the connecting section of the compres-sion gauge.

c. If the compression pressure is above themaximum specification, check the cylinderhead, valve surfaces and piston crown forcarbon deposits.Carbon deposits → Eliminate.

d. If the compression pressure is below the min-imum specification, pour a teaspoonful of en-gine oil into the spark plug bore and measureagain.Refer to the following table.

7. Install: Spark plug

8. Connect: Spark plug cap

EAS20730

CHECKING THE ENGINE OIL LEVEL1. Stand the vehicle on a level surface.NOTE:

Place the vehicle on a suitable stand. Make sure the vehicle is upright.


3. Check: Engine oil level

The engine oil level should be between theminimum level mark “a” and maximum levelmark “b”.Below the minimum level mark → Add therecommended engine oil to the proper level.

Compression gauge90890-03081

Engine compression testerYU-33223

Standard compression pressure1200 kPa (12.0 kg/cm2/300 rpm)

Minimum compression pressure1050 kPa (10.5 kg/cm2/300 rpm)

Maximum compression pressure1300 kPa (13.0 kg/cm2/300 rpm)

Compression pressure (with oil applied into the cylinder)

Reading Diagnosis

Higher than without oilPiston ring(s) wear or

damage → Repair.

Same as without oil

Piston, valves, cylinder head gasket or pis-ton possibly defec-tive → Repair.

Spark plug18 Nm (1.8 m•kg, 13 ft•lb)T

R..

a

b

ENGINE

3-11

CAUTION:

ECA13360

Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives or use engineoils with a grade of CD or higher and do notuse oils labeled “ENERGY CONSERVINGII”.

Do not allow foreign materials to enter thecrankcase.

NOTE:

Before checking the engine oil level, wait a fewminutes until the oil has settled.


5. Check the engine oil level again.NOTE:

Before checking the engine oil level, wait a fewminutes until the oil has settled.

EAS20810

CHANGING THE ENGINE OIL1. Start the engine, warm it up for several min-

utes, and then turn it off.2. Place a container under the engine oil drain

bolt.

3. Remove: Engine oil filler cap “1” Engine oil drain bolt “2”

(along with the gasket) Oil filter element drain bolt “3”

4. Drain: Engine oil

(completely from the crankcase)5. If the oil filter element is also to be replaced,

perform the following procedure.

a. Remove the oil filter element cover “1” and oilfilter element “2”.

b. Replace the O-rings “3”.align = "center"/>

c. Install the new oil filter element and the oil fil-ter element cover.

TypeYAMALUBE 4, SAE10W30 orSAE20W40

Recommended engine oil gradeAPI service SG type or higher,JASO standard MA

ACEA standardG4 or G5

10 30 50 70 90 1100 130 ˚F

YAMALUBE 4 (10W-30)or SAE 10W-30

YAMALUBE 4 (20W-40)or SAE 20W-40

–10 0 10 20 30 40–20 50 ˚C

Oil filter element cover bolt (M10)10 Nm (1.0 m•kg, 7.2 ft•lb)

2

New

TR..

ENGINE

3-12

6. Check: Engine oil drain bolt gasket Oil filter element drain bolt gasket

Damage → Replace.7. Install:

Engine oil drain bolt Oil filter element drain bolt

(along with the gasket)

8. Fill: Crankcase

(with the specified amount of the recom-mended engine oil)

9. Install: Engine oil filler cap

10.Start the engine, warm it up for several min-utes, and then turn it off.

11.Check: Engine

(for engine oil leaks)12.Check:

Engine oil levelRefer to “CHECKING THE ENGINE OILLEVEL” on page 3-12.

13.Check: Engine oil pressure

a. Slightly loosen the oil check bolt “1”.

b. Start the engine and keep it idling until engine

oil starts to seep from the oil check bolt. If no

engine oil comes out after one minute, turn

the engine off so that it will not seize.

c. Check the engine oil passages, the oil filter

cartridge and the oil pump for damage or

leakage. Refer to “INSTALL THE OIL PUMP

AND BALANCER GEAR” on page 5-41.

d. Start the engine after solving the problem(s)

and check the engine oil pressure again.

e. Tighten the oil check bolt to specification.

EAS20870

ADJUSTING THE CLUTCH CABLE FREE PLAY1. Check:

Clutch cable free play “a”Out of specification → Adjust.

2. Adjust: Clutch cable free play

Engine oil drain bolt20 Nm (2.0 m•kg, 15 ft•lb)

Oil filter element drain bolt10 Nm (1.0 m•kg, 7.2 ft•lb)

Engine oil quantityTotal amount

1.40 L (1.48 US qt) (1.23 Imp.qt)Without oil filter element replace-ment

1.20 L (1.27 US qt) (1.06 Imp.qt)With oil filter element replace-ment

1.30 L (1.37 US qt) (1.14 Imp.qt)

TR..

Oil check bolt7 Nm (0.7 m•kg, 5.1 ft•lb)

Clutch cable free play10.0–15.0 mm (0.39–0.59 in)

TR..

a

ENGINE

3-13

Clutch lever sidea. Slide rubber cover “1” from the clutch lever.b. Loosen the locknut “2”.c. Fully tighten the adjusting bolt “3”.d. Tighten the locknut “2”.e. Slide and return rubber cover “1” to original

position.

Clutch cable sidea. Slide rubber cover “1” from the clutch lever.b. Loosen the locknut “2”.c. Adjust the play of clutch cable by turning the

adjusting bolt “3” in direction “a” or “b”.

d. Tighten the locknut “2”.e. Slide and return rubber cover “1” to original

position.

EAS20961

REPLACING THE AIR FILTER ELEMENT1. Check:

Air filter check hose

NOTE:

Check the air filter check hose locating at thebottom of air filter case. If a foreign material suchas dust and water is found, replace the air filterelement. Also, clean the air filter case and air fil-ter check hose.

2. Remove: Seat

Refer to “GENERAL CHASSIS” on page 4-1.3. Remove:

Air filter case cap “1”

4. Check: Air filter element “1”

Damage/obstruction → Replace.NOTE:

Replace the air filter element every 20.000 km(12,427.42 mi) of operation.

The air filter needs more frequent service if youare riding in unusually wet or dusty areas.

5. Install: Air filter element Air filter case cap

CAUTION:

ECA14401

Never operate the engine without the air filterelement installed. Unfiltered air will causerapid wear of engine parts and may damagethe engine. Operating the engine without theair filter element will also affect carburetorsynchronization, leading to poor engine per-formance and possible overheating.

Direction “a”Increases the clutch cable play.Direction “b”Decreases the clutch cable play.

31

2

2

1

3b

a

1

1

ENGINE

3-14

NOTE:

Make sure that the air filter element is installedsecurely in the air filter case to prevent any airleaks.

6. Install: Seat

Refer to “GENERAL CHASSIS” on page 4-1.

EAS20990

CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD1. Remove:

Fuel tankRefer to “FUEL TANK” on page 6-1.

2. Check: Carburetor joint “1” Intake manifold “2”

Cracks/damage → Replace.Refer to “CARBURETOR” on page 6-3.

3. Install: Fuel tank

Refer to “FUEL TANK” on page 6-1.

EAS21030

CHECKING THE FUEL LINEThe following procedure applies to all of the fuel,vacuum and breather hoses.1. Remove:

Left fuel tank side coverRefer to “GENERAL CHASSIS” on page 4-1.

2. Check: Fuel hose “1” Vacuum hose Breather hose

Cracks/damage → Replace.Loose connection → Connect properly or re-place the clip hose.

3. Install: Left fuel tank side cover


EAS21050

CHECKING THE CYLINDER HEAD BREATHER HOSE1. Remove:

Left fuel tank side cover Right fuel tank side cover

Refer to “GENERAL CHASSIS” on page 4-1.2. Check:

Cylinder head breather hose “1”Cracks/damage → Replace.Loose connection → Connect properly.

CAUTION:

ECA14920

Make sure the cylinder head breather hose isrouted correctly.

3. Install: Right fuel tank side cover Left fuel tank side cover


EAS21080

CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes and gaskets.1. Check:

Exhaust pipe “1” Muffler “2”

Cracks/damage → Replace. Gasket

1

2

1

1

ENGINE

3-15

Exhaust gas leaks → Replace.2. Check:

Tightening torque Exhaust pipe nut “3” Exhaust pipe joint bolt “4” Muffler bolt “5”

Exhaust pipe nut18 Nm (1.8 m•kg, 13 ft•lb)

Exhaust pipe joint bolt20 Nm (2.0 m•kg, 15 ft•lb)

Muffler bolt42 Nm (4.2 m•kg, 30 ft•lb)

TR..

1

3

14

5

2

5

2

CHASSIS

3-16

EAS21140

CHASSIS

EAS21170

ADJUSTING THE FRONT DISC BRAKE1. Check:

Brake lever free play “a”Out of specification → Adjust.

2. Adjust: Brake lever free play

a. Loosen the locknut “1”.b. Turn the adjusting screw “2” in direction “a” or

“b” until the specified brake lever free play isobtained.

c. Tighten the locknut “1”.

WARNING

EWA13050

A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-

erably reduce braking performance.

CAUTION:

ECA13490

After adjusting the brake lever position,make sure there is no brake drag.

EAS21200

ADJUSTING THE REAR DISC BRAKE1. Check:

Brake pedal position(Height “b” from footrest position “a” to brakepedal top position)Out of specification → Adjust.

2. Adjust: Brake pedal position

a. Loosen the locknut “1”.b. Turn the adjusting nut “2” in direction “a” or

“b” until the specified brake pedal position isobtained.

Brake lever free play2.0–5.0 mm (0.08–0.20 in)

Direction “a”Brake lever free play is increased.Direction “b”Brake lever free play is decreased.

a

aa

bb

12

Brake pedal position20.0 mm (0.79 in)

Direction “a”Brake pedal is raised.Direction “b”Brake pedal is lowered.

b

a

a

b

2

1

CHASSIS

3-17

c. Tighten the locknut “1” to specification.

WARNING

EWA5UXB005

A soft or spongy feeling in the brake pedalcan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident. Therefore, check and, if neces-sary, bleed the brake system.

CAUTION:

ECA13510

After adjusting the brake pedal position,make sure there is no brake drag.

3. Adjust: Rear brake light switch

Refer to “ADJUSTING THE REAR BRAKELIGHT SWITCH” on page 3-20.

EAS21240

CHECKING THE BRAKE FLUID LEVEL1. Stand the vehicle on a level surface.NOTE:

Place the vehicle on a suitable stand. Make sure the vehicle is upright.

2. Check: Brake fluid level

Below the minimum level mark “a” → Add therecommended brake fluid to the proper level.

WARNING

EWA13090

Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.

Refill with the same type of brake fluid thatis already in the system. Mixing brake flu-ids may result in a harmful chemical reac-tion, leading to poor brake performance.

When refilling, be careful that water doesnot enter the brake fluid reservoir. Waterwill significantly lower the boiling point ofthe brake fluid and could cause vapor lock.

CAUTION:

ECA13540

Brake fluid may damage painted surfacesand plastic parts. Therefore, always clean upany spilt brake fluid immediately.

NOTE:

In order to ensure a correct reading of the brakefluid level, make sure the top of the brake fluidreservoir is horizontal.

EAS21250

CHECKING THE FRONT BRAKE PADSThe following procedure applies to all of thebrake pads.1. Operate the brake.

Locknut17 Nm (1.7 m•kg, 12.5 ft•lb)

Recommended fluidDOT 4

TR..

A. Front

B. Rear

a

A

a

B

CHASSIS

3-18

2. Check: Front brake pad

Wear indicator grooves “a” almost disap-peared → Replace the brake pads as a set.Refer to “FRONT BRAKE” on page 4-12.

EAS21260

CHECKING THE REAR BRAKE PADSThe following procedure applies to all of thebrake pads.1. Operate the brake.2. Check:

Rear brake padWear indicator grooves “a” almost disap-peared → Replace the brake pads as a set.Refer to “REAR BRAKE” on page 4-24.

EAS21270

CHECKING THE FRONT BRAKE HOSE1. Check:

Front brake hose “1”Cracks/damage/wear → Replace.

2. Check: Brake hose clamp

Loose connection → Tighten the clamp bolt.3. Hold the vehicle upright and apply the front

brake several times.4. Check:

Front brake hoseBrake fluid leakage → Replace the damagedhose.Refer to “FRONT BRAKE” on page 4-12.

EAS21290

CHECKING THE REAR BRAKE HOSE1. Check:

Front brake hose “1”Cracks/damage/wear → Replace.

2. Check: Brake hose clamp

Loose connection → Tighten the clamp bolt.3. Hold the vehicle upright and apply the rear

brake several times.4. Check:

Rear brake hoseBrake fluid leakage → Replace the damagedhose.Refer to “REAR BRAKE” on page 4-24.

EAS21330

ADJUSTING THE REAR BRAKE LIGHT SWITCHNOTE:

The rear brake light switch is operated by move-ment of the brake pedal. The rear brake light isproperly adjusted when the brake light comes onjust before the braking effect starts.

1. Check: Brake light operation timing

Incorrect → Adjust.2. Adjust:

Brake light operation timing

a. Hold the main body “1” of the rear brake lightswitch so that it does not rotate and turn theadjusting nut “2” in direction “a” or “b” until therear brake light comes on at the proper time.

a

a

a

1

1

CHASSIS

3-19

EAS21350

BLEEDING THE HYDRAULIC BRAKE SYSTEM

WARNING

EWA13100

Bleed the hydraulic brake system whenever: the system is disassembled. a brake hose is loosened, disconnected or

replaced. the brake fluid level is very low. brake operation is faulty.

1. Remove: Brake master cylinder reservoir cap

NOTE:

Be careful not to spill any brake fluid or allowthe brake master cylinder reservoir to overflow.

When bleeding the hydraulic brake system,make sure there is always enough brake fluidbefore applying the brake. Ignoring this pre-caution could allow air to enter the hydraulicbrake system, considerably lengthening thebleeding procedure.

If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours. Repeatthe bleeding procedure when the tiny bubblesin the hose have disappeared.

2. Bleed: Hydraulic brake system

a. Fill the brake fluid reservoir to the proper levelwith the recommended brake fluid.

b. Install the diaphragm (brake master cylinderreservoir or brake fluid reservoir).

c. Connect clear plastic hose “1” tightly to bleed

screw “2”, and place an oil pan under theplastic hose end.

d. Place the other end of the hose into a con-tainer.

e. Slowly apply the brake several times.f. Fully pull the brake lever or fully press down

the brake pedal and hold it in position.g. Loosen the bleed screw.NOTE:

Loosening the bleed screw will release the pres-sure and cause the brake lever to contact thethrottle grip or the brake pedal to fully extend.

h. Tighten the bleed screw and then release thebrake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the air bub-bles have disappeared from the brake fluid inthe plastic hose.

j. Tighten the bleed screw to specification.

k. Fill the brake fluid reservoir to the proper levelwith the recommended brake fluid.Refer to “CHECKING THE BRAKE FLUIDLEVEL” on page 3-19.

WARNING

EWA13110

After bleeding the hydraulic brake system,

Direction “a”Brake light comes on sooner.Direction “b”Brake light comes on later.

1

2

a b

A. Front

B. Rear

Bleed screw6 Nm (0.6 m•kg, 4.3 ft•lb)

2

1

A

2

1

B

TR..

CHASSIS

3-20

check the brake operation.

EAS21420

ADJUSTING THE DRIVE CHAIN SLACKNOTE:

The drive chain slack must be checked at thetightest point on the chain.

CAUTION:

ECA13550

A drive chain that is too tight will overloadthe engine and other vital parts, and one thatis too loose can skip and damage the swing-arm or cause an accident. Therefore, keepthe drive chain slack within the specified lim-its.

1. Stand the vehicle on a level surface.

WARNING

EWA13120

Securely support the vehicle so that there isno danger of it falling over.

NOTE:

Place the vehicle on a suitable stand so that therear wheel is elevated.

2. Spin the rear wheel several times and find thetightest position of drive chain.

3. Check: Drive chain slack “a”


NOTE:

Measure the drive chain slack in the intermedi-ate position between drive axle center and rearwheel axle center.

If the chain contacts the drive chain guide, thisis the limit of chain slack.

4. Adjust:

Drive chain slack

a. Loosen the wheel axle nut “1”.b. Turn the drive chain adjusting plate “2” in di-

rection “a” or “b” until the specified drive chainslack is obtained.

NOTE:

To maintain the proper wheel alignment, adjustboth sides evenly.

c. Tighten the wheel axle nut to specification.

EAS21440

LUBRICATING THE DRIVE CHAINThe drive chain consists of many interactingparts. If the drive chain is not maintained proper-ly, it will wear out quickly. Therefore, the drivechain should be serviced, especially when thevehicle is used in dusty areas.This vehicle has a drive chain with small rubberO-rings between each side plate. Steam clean-ing, high-pressure washing, certain solvents,and the use of a coarse brush can damagethese O-rings. Therefore, use only kerosene toclean the drive chain. Wipe the drive chain dryand thoroughly lubricate it with engine oil orchain lubricant that is suitable for O-ring chains.Do not use any other lubricants on the drivechain since they may contain solvents that coulddamage the O-rings.

Drive chain slack40.0–45.0 mm (1.57–1.77 in)

a

Direction “a”Drive chain is tightened.Direction “b”Drive chain is loosened.

Rear wheel axle nut85 Nm (8.5 m•kg, 62 ft•lb)

1

2

a

b

TR..

CHASSIS

3-21

EAS21510

CHECKING AND ADJUSTING THE STEERING HEAD1. Stand the vehicle on a level surface.

WARNING

EWA13120


NOTE:

Place the vehicle on a suitable stand so that thefront wheel is elevated.

2. Check: Steering head

Grasp around the outer tube of the front forklegs and gently rock the front fork.Binding/looseness → Adjust the steeringhead.

3. Remove: Upper bracket

Refer to “STEERING HEAD” on page 4-47.4. Adjust:

Steering head

a. Remove the lock washer “1”, the upper ringnut “2”, and the rubber washer “3”.

b. Loosen the lower ring nut “4” first, then usethe steering nut wrench “5” and retighten thenut with the specified torque. Next, check thesteering by turning it to the right and left a fewtimes.

NOTE:

Set the torque wrench at a right angle to thesteering nut wrench.

c. Loosen the lower ring nut “4” completely, andthen use the steering nut wrench and retight-en the nut with the specified torque.

WARNING

EWA13140

Do not overtighten the lower ring nut.

d. Check the steering head for looseness orbinding by turning the front fork all the way inboth directions. If any binding is felt, removethe lower bracket and check the upper andlower bearings.Refer to “STEERING HEAD” on page 4-47.

e. Install the rubber washer “3”.f. Install the upper ring nut “2”.g. Finger tighten the upper ring nut “2”, then

align the slots of both ring nuts. If necessary,hold the lower ring nut and tighten the upperring nut until their slots are aligned.

NOTE:

Make sure the lock washer tabs “a” sit correctlyin the ring nut slots “b”.

Recommended lubricantEngine oil or chain lubricantsuitable for O-ring chains

Steering nut wrench90890-01403

Spanner wrenchYU-33975

Lower ring nut (initial tighteningtorque)

38 Nm (3.8 m•kg, 2.8 ft•lb)

Lower ring nut (final tighteningtorque)

4 Nm (0.4 m•kg, 2.9 ft•lb)

TR..

TR..

CHASSIS

3-22

5. Install: Upper bracket

Refer to “STEERING HEAD” on page 4-47.

EAS21530

CHECKING THE FRONT FORK1. Stand the vehicle on a level surface.

WARNING

EWA13120


2. Check: Inner tube

Damage/scratches → Replace. Oil seal

Oil leakage → Replace.3. Hold the vehicle upright and apply the front

brake.4. Check:

Front fork operationPush down hard on the handlebar severaltimes and check if the front fork reboundssmoothly.Rough movement → Repair.Refer to “FRONT FORK” on page 4-39.

EAS21590

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

WARNING

EWA13120


Spring preload

CAUTION:

ECA13590

Never go beyond the maximum or minimumadjustment positions.

1. Adjust: Spring preload

NOTE:

Adjust the spring preload by removing the rearshock absorber.

a. Adjust the spring preload with a ring nutwrench.

b. Loosen the locknut “1”.c. When you turn adjusting ring “2” in direction

“a” or “b”, spring length “c” changes and youcan adjust the spring preload.

Ring nut wrench90890-01268


Direction “a”Spring preload is increased (suspensionis harder).Direction “b”Spring preload is decreased (suspensionis softer).

1b

a2

CHASSIS

3-23

d. Tighten the locknut.

EAS21650

CHECKING THE TIRESThe following procedure applies to both of thetires.1. Check:

Tire pressureOut of specification → Regulate.

WARNING

EWA13180

The tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperature.

The tire pressure and the suspension mustbe adjusted according to the total weight(including cargo, rider, passenger and ac-cessories) and the anticipated riding

speed. Operation of an overloaded vehicle could

cause tire damage, an accident or an injury.NEVER OVERLOAD THE VEHICLE.

WARNING

EWA13190

It is dangerous to ride with a worn-out tire.When the tire tread reaches the wear limit,replace the tire immediately.

2. Check: Tire surfaces

Damage/wear → Replace the tire.

Spring length “c”Standard

197.0 mmMinimum (hard)

187.0 mmMaximum (soft)

207.0 mm


c

TR..

Tire air pressure (measured oncold tires)

Loading condition0–90 kg (0–198 lb)

Front125 kPa (18 psi) (1.25 kgf/cm2)

Rear150 kPa (22 psi) (1.50 kgf/cm2)

Loading condition90 kg–Maximum load

Front150 kPa (22 psi) (1.50 kgf/cm2)

Rear175 kPa (25 psi) (1.75 kgf/cm2)

High-speed ridingFront

150 kPa (1.50 kgf/cm2)Rear

175 kPa (1.75 kgf/cm2)Maximum load

160 kg (353 lb)* Total weight of rider, passenger, cargo

and accessories

1. Tire tread depth

2. Side wall

3. Wear indicator

1

2 3

CHASSIS

3-24

WARNING

EWA14080

Do not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire fail-ure and personal injury from suddendeflation.

When using a tube tire, be sure to install thecorrect tube.

Always replace a new tube tire and a newtube as a set.

To avoid pinching the tube, make sure thewheel rim band and tube are centered in thewheel groove.

Patching a punctured tube is not recom-mended. If it is absolutely necessary to doso, use great care and replace the tube assoon as possible with a good quality re-placement.

WARNING

EWA14090

After extensive tests, the tires listed belowhave been approved by Yamaha Motor Co.,Ltd. for this model. The front and rear tiresshould always be by the same manufacturerand of the same design. No guarantee con-cerning handling characteristics can be giv-en if a tire combination other than oneapproved by Yamaha is used on this vehicle.

WARNING

EWA13210

New tires have a relatively low grip on theroad surface until they have been slightlyworn. Therefore, approximately 100 kmshould be traveled at normal speed beforeany high-speed riding is done.

NOTE:

Align the mark “1” with the valve installationpoint.

EAS21670

CHECKING THE WHEELSThe following procedure applies to both of thewheels.1. Check:

WheelDamage/out-of-round → Replace.

WARNING

EWA13260

Never attempt to make any repairs to thewheel.

NOTE:

After a tire or wheel has been changed or re-placed, always balance the wheel.

Wear limit (front)0.8 mm (0.03 in)

Wear limit (rear)0.8 mm (0.03 in)

Tube wheel Tube tire only

Tubeless wheel Tube or tubeless tire

Front tireSize

2.75-21 45PManufacturer/model

CHENG SHIN/C-6006Manufacturer/model

DUNLOP/D605F

Rear tireSize

120/80-18M/C 62PManufacturer/model

CHENG SHIN/C-6006Manufacturer/model

DUNLOP/D605

1

CHASSIS

3-25

EAS21680

CHECKING AND TIGHTENING THE SPOKESThe following procedure applies to all of thespokes.1. Check:

SpokeBends/damage → Replace.Loose → Tighten.Tap the spokes with a screwdriver.

NOTE:

A tight spoke will emit a clear, ringing tone; aloose spoke will sound flat.

2. Tighten: Spoke (Front/rear)

(with a spoke wrench “1” and torque wrench “2” )

3. Tighten: Spoke (Rear wheel)

NOTE:

Be sure to tighten the spokes before and afterbreak-in.

EAS21690

CHECKING AND LUBRICATING THE CABLESThe following procedure applies to all of the in-ner and outer cables.

WARNING

EWA13270

Damaged outer cable may cause the cable tocorrode and interfere with its movement. Re-place damaged outer cable and inner cablesas soon as possible.

1. Check: Outer cable

Damage → Replace.2. Check:

Cable operationRough movement → Lubricate.

NOTE:

Hold the cable end upright and pour a few dropsof lubricant into the cable sheath or use a suit-able lubricating device.

EAS21700

LUBRICATING THE LEVERSLubricate the pivoting point and metal-to-metalmoving parts of the levers.

EAS21710

LUBRICATING THE PEDALLubricate the pivoting point and metal-to-metalmoving parts of the pedal.

EAS21720

LUBRICATING THE SIDESTANDLubricate the pivoting point and metal-to-metalmoving parts of the sidestand.

EAS21740

LUBRICATING THE REAR SUSPENSIONLubricate the pivoting point and metal-to-metalmoving parts of the rear suspension.

Spoke (Front wheel)2 Nm (0.2 m•kg, 1.4 ft•lb)

Spoke wrench90890-01522

Spoke (Rear wheel)4 Nm (0.4 m•kg, 2.9 ft•lb)

TR..

1

2

TR..

Recommended lubricantEngine oil or a suitable cable lu-bricant

Clutch leverLithium-soap-based grease

Brake leverSilicone grease

Recommended lubricantLithium-soap-based grease


Recommended lubricantMolybdenum disulfide grease

ELECTRICAL SYSTEM

3-26

EAS21750

ELECTRICAL SYSTEM

EAS21760

CHECKING AND CHARGING THE BATTERYRefer to “ELECTRICAL COMPONENTS” onpage 7-29.

EAS21770

CHECKING THE FUSESRefer to “ELECTRICAL COMPONENTS” onpage 7-29.

EAS21780

REPLACING THE HEADLIGHT BULB1. Remove:

Headlight cowling “1”

2. Remove: Headlight unit bolts “1”

3. Disconnect: Headlight coupler “1” Bulb cover “2”

4. Remove: Headlight bulb holder “1”

WARNING

EWA13320

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

5. Install: Headlight bulb

Secure the new headlight bulb with the head-light bulb holder.

CAUTION:

ECA13690

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

6. Install: Headlight bulb holder Bulb cover Headlight coupler

7. Install: Headlight unit

EAS21800

ADJUSTING THE HEADLIGHT BEAM1. Adjust:

Headlight beam (vertically)

a. Turn the adjusting screw “1” in direction “a” or“b”.

1

1

1

2

Headlight unit bolt7 Nm (0.7 m•kg, 5.1 ft•lb)

Direction “a”Headlight beam is raised.Direction “b”Headlight beam is lowered.

1

New

TR..

ELECTRICAL SYSTEM

3-27

a b

1

2

3

4

5

6

7

8

9

CHASSIS

GENERAL CHASSIS .....................................................................................4-1

FRONT WHEEL .............................................................................................4-2REMOVING THE FRONT WHEEL ..........................................................4-4CHECKING THE FRONT WHEEL...........................................................4-4DISASSEMBLING THE FRONT WHEEL.................................................4-4ASSEMBLING THE FRONT WHEEL.......................................................4-5ADJUSTING THE FRONT WHEEL STATIC BALANCE..........................4-5INSTALLING THE FRONT WHEEL (DISC) .............................................4-6

REAR WHEEL................................................................................................4-8REMOVING THE REAR WHEEL (DISC).................................................4-10DISASSEMBLING THE REAR WHEEL...................................................4-10CHECKING THE REAR WHEEL .............................................................4-10CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..........4-10ASSEMBLING THE REAR WHEEL.........................................................4-11ADJUSTING THE REAR WHEEL STATIC BALANCE ............................4-11INSTALLING THE REAR WHEEL ...........................................................4-11

FRONT BRAKE..............................................................................................4-12INTRODUCTION......................................................................................4-17CHECKING THE FRONT BRAKE DISC..................................................4-17REPLACING THE FRONT BRAKE PADS...............................................4-18REMOVING THE FRONT BRAKE CALIPER...........................................4-19DISASSEMBLING THE FRONT BRAKE CALIPER.................................4-19CHECKING THE FRONT BRAKE CALIPER ...........................................4-19ASSEMBLING THE FRONT BRAKE CALIPER.......................................4-20INSTALLING THE FRONT BRAKE CALIPER .........................................4-20REMOVING THE FRONT BRAKE MASTER CYLINDER........................4-21CHECKING THE FRONT BRAKE MASTER CYLINDER ........................4-21ASSEMBLING THE FRONT BRAKE MASTER CYLINDER....................4-22INSTALLING THE FRONT BRAKE MASTER CYLINDER ......................4-22

REAR BRAKE................................................................................................4-24INTRODUCTION......................................................................................4-29CHECKING THE REAR BRAKE DISC ....................................................4-29REPLACING THE REAR BRAKE PADS .................................................4-29REMOVING THE REAR BRAKE CALIPER.............................................4-30DISASSEMBLING THE REAR BRAKE CALIPER ...................................4-30CHECKING THE REAR BRAKE CALIPER..............................................4-31ASSEMBLING THE REAR BRAKE CALIPER .........................................4-31INSTALLING THE REAR BRAKE CALIPER............................................4-31REMOVING THE REAR BRAKE MASTER CYLINDER ..........................4-32CHECKING THE REAR BRAKE MASTER CYLINDER...........................4-33ASSEMBLING THE REAR BRAKE MASTER CYLINDER ......................4-33INSTALLING THE REAR BRAKE MASTER CYLINDER.........................4-33

HANDLEBAR .................................................................................................4-35REMOVING THE HANDLEBARS ............................................................4-36

CHECKING THE HANDLEBAR ...............................................................4-36INSTALLING THE HANDLEBAR .............................................................4-36

FRONT FORK ................................................................................................4-39REMOVING THE FRONT FORK LEGS...................................................4-42DISASSEMBLING THE FRONT FORK LEGS.........................................4-42CHECKING THE FRONT FORK LEGS ...................................................4-43ASSEMBLING THE FRONT FORK LEGS...............................................4-43INSTALLING THE FRONT FORK LEGS .................................................4-46

STEERING HEAD ..........................................................................................4-47REMOVING THE LOWER BRACKET .....................................................4-49CHECKING THE STEERING HEAD........................................................4-49INSTALLING THE STEERING HEAD......................................................4-49

REAR SHOCK ABSORBER ASSEMBLY .....................................................4-51HANDLING THE REAR SHOCK ABSORBER.........................................4-52DISPOSING OF A REAR SHOCK ABSORBER ......................................4-52REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-52CHECKING THE REAR SHOCK ABSORBER ASSEMBLY....................4-52CHECKING THE CONNECTING ARM AND RELAY ARM......................4-52INSTALLING THE RELAY ARM ..............................................................4-52INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY..................4-53

SWINGARM ...................................................................................................4-54REMOVING THE SWINGARM ................................................................4-55CHECKING THE SWINGARM.................................................................4-55INSTALLING THE SWINGARM...............................................................4-55

CHAIN DRIVE ................................................................................................4-57REMOVING THE DRIVE CHAIN .............................................................4-58CHECKING THE DRIVE CHAIN..............................................................4-58CHECKING THE DRIVE SPROCKET .....................................................4-59INSTALLING THE DRIVE CHAIN............................................................4-59

GENERAL CHASSIS

4-1

EAS21830

GENERAL CHASSISRemoving the cowling


1 Seat 1

2 Rear left side cover 1

3 Rear right side cover 1

4 Left fuel tank side cover 1

5 Right fuel tank side cover 1

6 Front left side cover 1

7 Front right side cover 1

8 Tool box 1


TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib) TR..

4 Nm (0.4 m • kg, 2.9 ft • Ib)

TR..

9 Nm (0.9 m • kg, 6.5 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

1

2

46

7

5

3 8

FRONT WHEEL

4-2

EAS21870

FRONT WHEELRemoving the front wheel and brake disc


NOTE:Use a suitable stand to raise the front wheel

off the ground.

1 Front wheel axle nut 1

2 Front wheel axle 1

3 Front wheel assembly 1

4 Collar/dust seal 2/2

5 Front brake disc 1


LT

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

85 Nm (8.5 m • kg, 62 ft • Ib)

1

2

3

4

4

5

(6)

FRONT WHEEL

4-3

Disassembling the front wheel


1 Oil seal 2

2 Wheel bearing 2

3 Spacer 1

For assembly, reverse the disassembly pro-cedure.

1

2

2

3

1 New

New

FRONT WHEEL

4-4

EAS21890

REMOVING THE FRONT WHEEL1. Stand the vehicle on a level surface.

WARNING

EWA13120


2. Elevate: Front wheel

NOTE:


EAS21930

CHECKING THE FRONT WHEEL1. Check:

Front wheel axleRoll the wheel axle on a flat surface.Bends → Replace.

WARNING

EWA13460

Do not attempt to straighten a bent wheel ax-le.

2. Check: Tire Front wheel

Damage/wear → Replace.Refer to “CHECKING THE TIRES” on page3-23 and “CHECKING THE WHEELS” onpage 3-24.

3. Check: Spokes

Bends/damage → Replace.Loose → Tighten.Refer to “CHECKING AND TIGHTENINGTHE SPOKES” on page 3-25.

NOTE:

After tightening the spokes, measure the frontwheel runout.

4. Measure: Front wheel radial runout “a” Front wheel lateral runout “b”

Over the specified limits → Replace.

5. Check: Collars

Damage/wear → Replace.6. Check:

Wheel bearingsFront wheel turns roughly or is loose → Re-place the wheel bearings.

Oil sealsDamage/wear → Replace.

EAS21910

DISASSEMBLING THE FRONT WHEEL1. Remove:

Oil seals Wheel bearings

a. Clean the outside of the front wheel hub.b. Remove the oil seals “1” with a flat-head

screwdriver.NOTE:

To prevent damaging the wheel, place a rag “2”between the screwdriver and the wheel surface.

Radial wheel runout limit2.0 mm (0.08 in)

Lateral wheel runout limit2.0 mm (0.08 in)

a

b

FRONT WHEEL

4-5

c. Remove the wheel bearings with a generalbearing puller.

EAS21960

ASSEMBLING THE FRONT WHEEL1. Install:

Wheel bearings Oil seals Spacer

a. Install the new wheel bearings and oil seals inthe reverse order of disassembly.

CAUTION:

EC3C51001

Do not contact the wheel bearing inner race“1”or balls “2”. Support with the outer race“3”.

NOTE:

Use a socket “4” that matches the diameter ofthe wheel bearing outer race and oil seal.

EAS21970

ADJUSTING THE FRONT WHEEL STATIC BALANCENOTE:

After replacing the tire, wheel or both, the frontwheel static balance should be adjusted.

Adjust the front wheel static balance with thebrake disc installed.

1. Remove: Balancing weight(s)

2. Find: Front wheel’s heavy spot

NOTE:

Place the front wheel on a suitable balancingstand.

a. Spin the front wheel.b. When the front wheel stops, put an “X1” mark

at the bottom of the wheel.

c. Turn the front wheel 90° so that the “X1” markis positioned as shown.

d. Release the front wheel.e. When the wheel stops, put an “X2” mark at

the bottom of the wheel.

1

2

New

1

2

3

4

FRONT WHEEL

4-6

f. Repeat steps (d) through (f) several times un-til all the marks come to rest at the same spot.

g. The spot where all the marks come to rest isthe front wheel’s heavy spot “X”.

3. Adjust: Front wheel static balance

a. Install a balancing weight “1” onto the rim ex-actly opposite the heavy spot “X”.

NOTE:

Start with the lightest weight.

b. Turn the front wheel 90° so that the heavyspot is positioned as shown.

c. If the heavy spot does not stay in that posi-tion, install a heavier weight.

d. Repeat steps (b) and (c) until the front wheelis balanced.

4. Check: Front wheel static balance

a. Turn the front wheel and make sure it stays ateach position shown.

b. If the front wheel does not remain stationaryat all of the positions, rebalance it.

EAS22000

INSTALLING THE FRONT WHEEL (DISC)The following procedure applies to both of thebrake discs.1. Install:

Front brake discRefer to “CHECKING THE FRONT BRAKEDISC” on page 4-17.

2. Lubricate: Front wheel axle Oil seal lips

3. Tighten: Front wheel axle nut “1”


1

FRONT WHEEL

4-7

WARNING

EWA13500

Make sure the brake hose is routed properly.

CAUTION:

ECA14140

Before tightening the wheel axle nut, pushdown hard on the handlebar(s) several timesand check if the front fork rebounds smooth-ly.

Front axle nut85 Nm (8.5 m•kg, 62 ft•lb)T

R..

REAR WHEEL

4-8

EAS22020

REAR WHEELRemoving the rear wheel, brake disc and rear wheel sprocket


NOTE:Use a suitable stand to raise the rear wheel off

the ground.

1 Drive chain case 1

2 Rear wheel axle nut 1

3 Drive chain adjusting plate 2

4 Rear wheel axle 1

5 Drive chain 1

6 Rear wheel assembly 1

7 Collar/dust cover 1/1

8 Collar/dust cover 1/1

9 Rear brake disc 1

10 Rear wheel sprocket 1


LT

LT

TR..

4 Nm (0.4 m • kg, 2.9 ft • Ib)

TR..

85 Nm (8.5 m • kg, 62 ft • Ib)

TR..

33 Nm (3.3 m • kg, 24 ft • Ib)

TR..

28 Nm (2.8 m • kg, 21 ft • Ib)

8

4

3

9

(3)

(6)

7

10

6

1

5

32

REAR WHEEL

4-9

Disassembling the rear wheel


1 Oil seal 2

2 Wheel bearing 3

3 Spacer 1


1

23

1

2

New

New

REAR WHEEL

4-10

EAS22040

REMOVING THE REAR WHEEL (DISC)1. Stand the vehicle on a level surface.

WARNING

EWA13120


NOTE:


2. Elevate: Rear wheel

3. Remove: Drive chain case Rear wheel axle nut Drive chain adjusting plate “1” Rear wheel axle “2” Rear wheel “3”

NOTE:

Push the rear wheel forward and remove thedrive chain from the rear wheel sprocket.

EAS22080

DISASSEMBLING THE REAR WHEEL1. Remove:

Oil seals Wheel bearings

Refer to “DISASSEMBLING THE FRONTWHEEL” on page 4-4.

EAS22100

CHECKING THE REAR WHEEL1. Check:

Rear wheel axle Rear wheel Wheel bearings Oil seals

Refer to “CHECKING THE FRONT WHEEL”on page 4-4.

2. Check: Tire Rear wheel

Damage/wear → Replace.

Refer to “CHECKING THE TIRES” on page3-23 and “CHECKING THE WHEELS” onpage 3-24.

3. Check: Spokes

Bends/damage → Replace.Loose → Tighten.Refer to “CHECKING THE FRONT WHEEL”on page 4-4.

4. Measure: Radial rear wheel runout Lateral rear wheel runout

Refer to “CHECKING THE FRONT WHEEL”on page 4-4.

EAS22120

CHECKING AND REPLACING THE REAR WHEEL SPROCKET1. Check:

Rear wheel sprocketMore than 1/4 tooth “a” wear → Replace thedrive chain, drive sprocket, and rear wheelsprocket as a set.Bent teeth → Replace the drive chain, drivesprocket, and rear wheel sprocket as a set.

2. Replace: Rear wheel sprocket

a. Remove the self-locking nuts and the rearwheel sprocket.

b. Clean the rear wheel drive hub with a cleancloth, especially the surfaces that contact thesprocket.

c. Install the new rear wheel sprocket.

21

3

Radial wheel runout limit2.0 mm (0.08 in)

Lateral wheel runout limit2.0 mm (0.08 in)

a. 1/4 wear

b. Correct

1. Drive chain roller

2. Rear wheel sprocket

1

2

a

b

REAR WHEEL

4-11

NOTE:

Tighten the self-locking nuts in stages and in acrisscross pattern.

EAS22140

ASSEMBLING THE REAR WHEEL1. Install:

Wheel bearings Oil seals

Refer to “ASSEMBLING THE FRONTWHEEL” on page 4-5.

Spacer

EAS22150

ADJUSTING THE REAR WHEEL STATIC BALANCENOTE:

After replacing the tire, wheel or both, the rearwheel static balance should be adjusted.

Adjust the rear wheel static balance with thebrake disc and drive sprocket installed.

1. Adjust: Rear wheel static balance

Refer to “ADJUSTING THE FRONT WHEELSTATIC BALANCE” on page 4-5.

EAS22160

INSTALLING THE REAR WHEEL1. Install:

Rear brake discRefer to “CHECKING THE REAR BRAKEDISC” on page 4-29.

2. Lubricate: Rear wheel axle Oil seal lips

3. Adjust: Drive chain slack

Refer to “ADJUSTING THE DRIVE CHAINSLACK” on page 3-20.

4. Tighten: Rear wheel axle nut

Rear wheel sprocket self-lockingnut

33 Nm (3.3 m•kg, 29 ft•lb)

TR..

New



Rear wheel axle nut85 Nm (8.5 m•kg, 62 ft•lb)T

R..

FRONT BRAKE

4-12

EAS22210

FRONT BRAKERemoving the front brake pads


1 Front brake caliper support bolt 1NOTE:Remove the lower parts only.

2 Front brake caliper assembly 1

NOTE:Lift and remove the front brake caliper assem-

bly.

3 Front brake pad 2

4 Brake pad shim 1

5 Brake pad spring 2


S

TR..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

TR..

32 Nm (3.2 m • kg, 23 ft • Ib)

1

2

54

3

5

FRONT BRAKE

4-13

Removing the front brake master cylinder


Drain the brake fluidRefer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19.

1 Right rear view mirror 1

2 Brake lever 1

3 Front brake light switch 1

4 Union bolt 1

5 Copper washer 2

6 Front brake hose 1

7 Brake master cylinder reservoir cap 1

8Brake master cylinder reservoir diaphragm holder

1

9 Brake master cylinder reservoir diaphragm 1

10 Front brake master cylinder holder 1

11 Front brake master cylinder 1


New

S

S

S

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

30 Nm (3.0 m • kg, 22 ft • Ib)

1

2

5

4

6

3

11

9

8

7 10

FRONT BRAKE

4-14

Disassembling the front brake master cylinder


1 Master cylinder kit 1


1New

BF

FRONT BRAKE

4-15

Removing the front brake calipers



1 Union bolt 1

2 Copper washer 2

3 Front brake hose 1

4 Front brake caliper support bolt 2

5 Front brake caliper assembly 1

6 Front brake pad 2

7 Brake pad shim 1


9 Front brake caliper bracket 1


New

S

S

TR..

40 Nm (4.0 m • kg, 29 ft • Ib)

TR..

30 Nm (3.0 m • kg, 22 ft • Ib)8

8

9

54

2

1

3

4

6

7

TR..

32 Nm (3.2 m • kg, 23 ft • Ib)

TR..

32 Nm (3.2 m • kg, 23 ft • Ib)

FRONT BRAKE

4-16

Disassembling the front brake calipers


1 Brake caliper piston 2

2 Brake caliper piston seal 2

3 Brake caliper dust seal 2

4 Bleed screw 1


1

3

2

4

New

New

TR..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

BF

S

FRONT BRAKE

4-17

EAS22220

INTRODUCTION

WARNING

EWA14100

Disc brake components rarely require disas-sembly. Therefore, always follow these pre-ventive measures: Never disassemble brake components un-

less absolutely necessary. If any connection on the hydraulic brake

system is disconnected, the entire brakesystem must be disassembled, drained,cleaned, properly filled, and bled after reas-sembly.

Never use solvents on internal brake com-ponents.

Use only clean or new brake fluid for clean-ing brake components.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always clean upany spilt brake fluid immediately. Avoid brake fluid coming into contact with

the eyes as it can cause serious injury.FIRST AID FOR BRAKE FLUID ENTERINGTHE EYES:Flush with water for 15 minutes and get im-mediate medical attention.

EAS22230

CHECKING THE FRONT BRAKE DISC1. Remove:

Front wheelRefer to “FRONT WHEEL” on page 4-2.

2. Check: Front brake disc

Damage/galling → Replace.3. Measure:

Brake disc deflectionOut of specification → Correct the brake discdeflection or replace the brake disc.

a. Place the vehicle on a suitable stand so thatthe front wheel is elevated.

b. Before measuring the front brake disc deflec-tion, turn the handlebar to the left or right toensure that the front wheel is stationary.

c. Remove the brake caliper.d. Hold the dial gauge at a right angle against

the brake disc surface.e. Measure the deflection at the point 13 mm

(front brake) or 14 mm (rear brake) below theedge of brake disc.

4. Measure: Brake disc thickness

Measure the brake disc thickness at a few dif-ferent locations.Out of specification → Replace.

5. Adjust: Brake disc deflection

a. Remove the brake disc.b. Turn the brake disc by one bolt hole.c. Install the brake disc.NOTE:

Tighten the brake disc bolts in stages and in acrisscross pattern.

Brake disc deflection limit0.15 mm (0.0059 in)

Brake disc thickness limit3.0 mm (0.12 in)

FRONT BRAKE

4-18

d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment

steps until the brake disc deflection is withinspecification.

f. If the brake disc deflection cannot be broughtwithin specification, replace the brake disc.

6. Install: Front wheel

Refer to “FRONT WHEEL” on page 4-2.

EAS22280

REPLACING THE FRONT BRAKE PADSNOTE:

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disassem-ble the brake caliper.

1. Measure: Brake pad wear limit “a”

Out of specification → Replace the brakepads as a set.

2. Install: Brake pad shims

(onto the inner brake pads) Front brake pads Brake pad spring

NOTE:

Always install new brake pads, brake pad shims,and a brake pad spring as a set.

a. Connect a clear plastic hose “1” tightly to thebleed screw “2”. Put the other end of the hoseinto an open container. The oil pan must beunder the hose end to receive the drain oil.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper with yourfinger.

c. Tighten the bleed screw.

d. Install new brake pads, new brake padshims, and a new brake pad spring.

3. Lubricate: Front brake caliper support bolt

Brake disc bolt10 Nm (1.0 m•kg, 7.2 ft•lb)Apply locking agent (LOC-TITE®)

Brake pad lining thickness (inner)5.3 mm (0.21 in)

Limit0.8 mm (0.03 in)

Brake pad lining thickness (outer)5.3 mm (0.21 in)


LT

TR..


2

1

TR..

FRONT BRAKE

4-19

CAUTION:

ECA14150

Do not allow grease to contact the brakepads.

Remove any excess grease.

4. Install: Front brake caliper


Below the minimum level mark “a” → Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” on page 3-17.


Soft or spongy feeling → Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” on page 3-19.

EAS22290

REMOVING THE FRONT BRAKE CALIPERNOTE:

Before disassembling the brake caliper, drainthe brake fluid from the entire brake system.

1. Remove: Union bolt Copper washers Brake hose

NOTE:

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

EAS22320

DISASSEMBLING THE FRONT BRAKE CALIPER1. Remove:

Brake caliper pistons “1” Brake caliper piston seals “2” Brake caliper dust seals “3”

a. Blow compressed air into the brake hose jointopening “a” to force out the pistons from thebrake caliper.

WARNING

EWA13560

Cover the brake caliper pistons with a rag.Be careful not to get injured when the pis-tons are expelled from the brake caliper.

Never try to pry out the brake caliper pis-tons.

b. Remove the brake caliper piston seals anddust seals.

EAS22390

CHECKING THE FRONT BRAKE CALIPER

Front brake caliper support boltSilicone grease

Brake caliper support bolt32 Nm (3.2 m•kg, 24 ft•lb)T

R..

a

Recommended brake component replacement schedule

Brake pads If necessary

Piston seals / dust seals Every two years

Brake hoses Every four years

Brake fluidEvery four years and whenever the brake is dis-assembled

13

2

a

FRONT BRAKE

4-20

1. Check: Brake caliper pistons “1”

Rust/scratches/wear → Replace the brakecaliper pistons.

Brake caliper cylinders “2”Scratches/wear → Replace the brake caliperassembly.

Brake caliper body “3”Cracks/damage → Replace the brake caliperassembly.

Brake fluid delivery passages(brake caliper body)Obstruction → Blow out with compressed air.

WARNING

EWA13610

Whenever a brake caliper is disassembled,replace the brake caliper piston seals.

2. Check: Brake caliper bracket

Cracks/damage → Replace.

EAS22400

ASSEMBLING THE FRONT BRAKE CALIPER

WARNING

EWA13620

Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.

Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.


EAS22420

INSTALLING THE FRONT BRAKE CALIPER1. Install:

Front brake caliper bracket Front brake caliper

(temporarily)

Copper washers Front brake hose Union bolt

WARNING

EWA13530

Proper brake hose routing is essential to in-sure safe vehicle operation. Refer to “CA-BLE ROUTING” on page 2-25.

CAUTION:

ECA14170

When installing the brake hose onto thebrake caliper “1”, make sure the brake pipe“a” touches the projection “b” on the brakecaliper.

2. Remove: Front brake caliper

3. Install: Brake pad springs Front brake pad Front brake caliper Brake caliper support bolt

Refer to “REPLACING THE FRONT BRAKEPADS” on page 4-18.

4. Fill: Brake master cylinder reservoir

(with the specified amount of the recom-mended brake fluid)

WARNING

EWA13090

Use only the designated brake fluid. Other


2

1

3

Front brake caliper bracket bolt40 Nm (4.0 m•kg, 29 ft•lb)

Union bolt30 Nm (3.0 m•kg, 22 ft•lb)

Brake caliper support bolt32 Nm (3.2 m•kg, 23 ft•lb)


New

TR..

1

ba

TR..

FRONT BRAKE

4-21

brake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.



CAUTION:

ECA13540


5. Bleed: Brake system

Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” on page 3-19.



7. Check: Brake lever operation


EAS22490

REMOVING THE FRONT BRAKE MASTER CYLINDERNOTE:

Before removing the front brake master cylinder,drain the brake fluid from the entire brake sys-tem.

1. Disconnect: Front brake light switch “1”

(from the brake switch)NOTE:

Remove the master cylinder by pressing theprojection.

2. Remove: Union bolt Copper washers Front brake hose

NOTE:

To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

EAS22500

CHECKING THE FRONT BRAKE MASTER CYLINDER1. Check:

Front brake master cylinder “1”Damage/scratches/wear → Replace.

Brake fluid delivery passages “2”(brake master cylinder body)Obstruction → Blow out with compressed air.

2. Check: Brake master cylinder kit “1”

Damage/scratches/wear → Replace.3. Check:

Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm

holder Brake master cylinder reservoir diaphragm

Cracks/damage → Replace.4. Check:

a

1

2

FRONT BRAKE

4-22

Front brake hoseCracks/damage/wear → Replace.

EAS22520

ASSEMBLING THE FRONT BRAKE MASTER CYLINDER

WARNING

EWA13520



1. Install: Cylinder cup “1” Master cylinder piston “2”

Use the cylinder cup installer “3” for installa-tion.

2. Install: Master cylinder piston Circlip “1” Dust boot “2”

EAS22530

INSTALLING THE FRONT BRAKE MASTER CYLINDER1. Install:

Front brake master cylinder “1”

NOTE:

Install the brake master cylinder holder with the“UP” mark facing up.

Align the end of the brake master cylinder hold-er with the punch mark “a” on the handlebar.

First, tighten the upper bolt, then the lower bolt.

2. Install: Copper washers “1” Brake hose “2” Union bolt “3”

WARNING

EWA13530


NOTE:

Hold the brake hose, and tighten the union boltso that the hose comes within the angle asshown.

Turn the handlebar to the left and right to makesure the brake hose does not touch other parts(e.g., wire harness, cables, leads). Correct ifnecessary.



New

New

Front brake master cylinder hold-er bolt

7 Nm (0.7 m•kg, 5.1 ft•lb)

Union bolt30 Nm (3.0 m•kg, 22 ft•lb)

TR..

a

1

New

TR..

FRONT BRAKE

4-23

3. Fill: Brake master cylinder reservoir


WARNING

EWA13540



When refilling, be careful that water doesnot enter the brake master cylinder reser-voir. Water will significantly lower the boil-ing point of the brake fluid and could causevapor lock.

CAUTION:

ECA13540







Soft or spongy feeling → Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” on page 3-19.Recommended fluid

DOT 4

2

1

3

New

15 25˚

a

REAR BRAKE

4-24

EAS22550

REAR BRAKERemoving the rear brake pads


Rear wheel Refer to “REAR WHEEL” on page 4-8.

1 Rear brake caliper cover 1

2 Brake pad support bolt 2

3 Rear brake pad 2

4 Rear brake caliper bracket 1


6 Rear brake caliper assembly 1


S

6

2

1

3

4

5

25

ST

R..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

17 Nm (1.7 m • kg, 12 ft • Ib)

REAR BRAKE

4-25

Removing the rear brake master cylinder



1 Union bolt 1

2 Copper washer 2

3 Rear brake hose 1

4 Cotter pin 1

5 Brake master cylinder reservoir cap 1

6Brake master cylinder reservoir diaphragm holder

1

7 Brake master cylinder reservoir diaphragm 1

8 Rear brake master cylinder 1


1

2

3

4

5

6

7

8

New

New

TR..

13 Nm (1.3 m • kg, 9.4 ft • Ib)

TR..

30 Nm (3.0 m • kg, 22 ft • Ib)

TR..

13 Nm (1.3 m • kg, 9.4 ft • Ib)

REAR BRAKE

4-26

Disassembling the rear brake master cylinder


1 Master cylinder kit 1


1New ST

R..

17 Nm (1.7 m • kg, 12 ft • Ib)

BF

REAR BRAKE

4-27

Removing the rear brake calipers




1 Rear brake caliper cover 1

2 Rear brake hose 1

3 Brake hose joint 1

4 Copper washer 1

5 Brake pad support bolt 2

6 Rear brake pad 2

7 Rear brake caliper bracket 1


9 Rear brake caliper assembly 1


9

2

3

4

5

5

7

8

8

1

6

New

S

S

TR..

14 Nm (1.4 m • kg, 10 ft • Ib)

TR..

26 Nm (2.6 m • kg, 19 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

17 Nm (1.7 m • kg, 12 ft • Ib)

REAR BRAKE

4-28

Disassembling the rear brake calipers


1 Brake caliper piston 1

2 Brake caliper piston seal 2

3 Brake caliper dust seal 2

4 Bleed screw 1


4

2

1

NewT

R..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

3 New

REAR BRAKE

4-29

EAS22560

INTRODUCTION

WARNING

EWA14100

Disc brake components rarely require disas-sembly. Therefore, always follow these pre-ventive measures: Never disassemble brake components un-

less absolutely necessary. If any connection on the hydraulic brake

system is disconnected, the entire brakesystem must be disassembled, drained,cleaned, properly filled, and bled after reas-sembly.


Use only clean or new brake fluid for clean-ing brake components.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always clean upany spilt brake fluid immediately. Avoid brake fluid coming into contact with

the eyes as it can cause serious injury.FIRST AID FOR BRAKE FLUID ENTERINGTHE EYES:Flush with water for 15 minutes and get im-mediate medical attention.

EAS22570

CHECKING THE REAR BRAKE DISC1. Remove:

Rear wheelRefer to “REAR WHEEL” on page 4-8.

2. Check: Rear brake disk

Damage/galling → Replace.3. Measure:

Brake disc deflectionOut of specification → Correct the brake discdeflection or replace the brake disc.Refer to “CHECKING THE FRONT BRAKEDISC” on page 4-17.

4. Measure: Brake disc thickness

Measure the brake disc thickness at a few dif-ferent locations.Out of specification → Replace.Refer to “CHECKING THE FRONT BRAKEDISC” on page 4-17.

5. Adjust: Brake disc deflection

Refer to “CHECKING THE FRONT BRAKEDISC” on page 4-17.

6. Install: Rear wheel

Refer to “REAR WHEEL” on page 4-8.

EAS22580

REPLACING THE REAR BRAKE PADSNOTE:

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disassem-ble the brake caliper.

1. Measure: Brake pad wear limit “a”

Out of specification → Replace the brakepads as a set.

2. Lubricate: Support pin

(Rear brake caliper or rear brake caliperbracket)

Brake pad support bolt

Brake disc deflection limit0.15 mm (0.0059 in)

Brake disc thickness limit4.0 mm (0.16 in)

Brake disc bolt28 Nm (2.8 m•kg, 21 ft•lb)Apply locking agent (LOC-TITE®)

Brake pad lining thickness (inner)5.2 mm (0.20 in)


Brake pad lining thickness (outer)5.2 mm (0.20 in)


TR..

a

REAR BRAKE

4-30

CAUTION:

ECA14150

Do not allow grease to contact the brakepads.

Remove any excess grease.

3. Install: Rear brake pad Brake pad spring Rear brake caliper bracket

NOTE:

Always install new brake pads, brake pad shims,and a brake pad spring as a set.

a. Connect a clear plastic hose “2” tightly to thebleed screw “1”. Put the other end of the hoseinto an open container. The oil pan must beunder the hose end to receive the drain oil.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper with yourfinger.

c. Tighten the bleed screw.

d. Install new brake pads and a new brake padspring.

4. Install: Brake pad support bolt Rear brake caliper cover


Below minimum level mark “a” → Add therecommended brake fluid to proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” on page 3-17.

6. Check: Brake pedal operation


EAS22590

REMOVING THE REAR BRAKE CALIPERNOTE:

Before disassembling the brake caliper, drainthe brake fluid from the entire brake system.

1. Remove: Rear brake hose Brake hose joint Copper washers

NOTE:

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

EAS22600

DISASSEMBLING THE REAR BRAKE CALIPER1. Remove:

Brake caliper piston “1” Brake caliper piston seal “2” Brake caliper dust seal “3”

Brake pad support boltSilicone grease


Brake pad support bolt17 Nm (1.7 m•kg, 13 ft•lb)

Rear brake caliper cover bolt7 Nm (0.7 m•kg, 5.1 ft•lb)

1

2

TR..

TR..

a

21

3

REAR BRAKE

4-31

a. Blow compressed air into the brake hose jointopening “a” to force out the piston from thebrake caliper.

WARNING

EWA13560

Cover the brake caliper pistons with a rag.Be careful not to get injured when the pis-tons are expelled from the brake caliper.

Never try to pry out the brake caliper pis-tons.

b. Remove the brake caliper piston seal anddust seal.

EAS22640

CHECKING THE REAR BRAKE CALIPER

1. Check: Brake caliper pistons “1”

Rust/scratches/wear → Replace the brakecaliper pistons.

Brake caliper cylinders “2”Scratches/wear → Replace the brake caliperassembly.

Brake caliper body “3”Cracks/damage → Replace the brake caliperassembly.

Brake fluid delivery passages(brake caliper body)Obstruction → Blow out with compressed air.

WARNING

EWA13610


2. Check: Brake caliper brackets “1”

Cracks/damage → Replace.

EAS22650

ASSEMBLING THE REAR BRAKE CALIPER

WARNING

EWA13620


Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.


EAS22670

INSTALLING THE REAR BRAKE CALIPER1. Install:

Rear brake caliper Rear brake caliper bracket

2. Rear wheel(temporarily)Refer to “REAR WHEEL” on page 4-8.

3. Install: Copper washer “1” Brake hose joint “2” Locknut “3” Rear brake hose “4”

Recommended brake componentReplacement schedule

Brake pads If necessary

Piston seal/dust seal Every two years

Brake hoses Every four years

Brake fluidEvery four years and whenever the brake is dis-assembled

a


3

1

2

New

REAR BRAKE

4-32

WARNING

EWA13530


4. Remove: Rear wheel Rear brake caliper bracket Rear brake caliper

5. Install: Brake pad springs Rear brake caliper bracket Rear brake pads Brake pad support bolts Brake caliper

Refer to “REPLACING THE REAR BRAKEPADS” on page 4-29.

6. Install: Rear wheel

Refer to “REAR WHEEL” on page 4-8.7. Fill:


Brake master cylinder reservoir

WARNING

EWA13090

Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poor

brake performance. Refill with the same type of brake fluid that

is already in the system. Mixing brake flu-ids may result in a harmful chemical reac-tion, leading to poor brake performance.


CAUTION:

ECA13540






10.Check: Brake pedal operation


EAS22700

REMOVING THE REAR BRAKE MASTER CYLINDERBefore disassembling the rear brake master cyl-inder, drain the brake fluid from the entire brakesystem.1. Remove:

Union bolt Copper washers Brake hose

NOTE:

To collect any remaining brake fluid, place a

Brake hose joint (caliper side)26 Nm (2.6 m•kg, 19 ft•lb)

Brake hose joint (hose side)14 Nm (1.4 m•kg, 10 ft•lb)

Brake pad support bolt17 Nm (1.7 m•kg, 13 ft•lb)


TR..

4

3

2

1 New

TR..

a

REAR BRAKE

4-33

container under the master cylinder and the endof the brake hose.

EAS22710

CHECKING THE REAR BRAKE MASTER CYLINDER1. Check:

Rear brake master cylinder “1”Damage/scratches/wear → Replace.

Brake fluid delivery passages “2”(brake master cylinder body)Obstruction → Blow out with compressed air.

2. Check: Brake master cylinder kit “1”

Damage/scratches/wear → Replace.

3. Check: Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm

holder Brake master cylinder reservoir diaphragm


Rear brake hoseCracks/damage/wear → Replace.

EAS22730

ASSEMBLING THE REAR BRAKE MASTER CYLINDER

WARNING

EWA13520



1. Install: Cylinder cup “1” Master cylinder piston “2”

Install it using with cylinder cup installer “3”.

2. Assemble: Spring“1” Master cylinder piston “2” Adjusting rod “3” Circlip“4” Dust boot“5”

EAS22750

INSTALLING THE REAR BRAKE MASTER CYLINDER1. Install:

Copper washers Brake hoses Union bolt

WARNING

EWA13530


CAUTION:

ECA14160

When installing the brake hose onto thebrake master cylinder, make sure the brakepipe touches the projection “a” as shown.


1 2

New


Brake hose union bolt30 Nm (3.0 m•kg, 22 ft•lb)

New

New

TR..

REAR BRAKE

4-34

2. Add the recommended brake fluid to theproper level.

Brake master cylinder reservoir

WARNING

EWA13090




CAUTION:

ECA13540









a

HANDLEBAR

4-35

EAS22840

HANDLEBARRemoving the handlebar


1 Back view mirror 2

2 Front brake light switch 1

3 Front brake master cylinder holder 1

4 Front brake master cylinder assembly 1

5 Right handlebar switch 1

6 Throttle cable housing 1

7 Throttle cable 2

8 Throttle grip 1

9 Clutch cable 1

10 Clutch switch 1

11 Clutch lever holder 1

12 Clutch lever assembly 1

13 Left handlebar switch 1

14 Handlebar grip 1

15 Special washer 1

16 Handlebar holder 2

17 Handlebar 1


1

86

5

3

4

2

7

9

16

17

12

10

6

13

1

11

14

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

23 Nm (2.3 m • kg, 17 ft • Ib)

15

HANDLEBAR

4-36

EAS22860

REMOVING THE HANDLEBARS1. Stand the vehicle on a level surface.

WARNING

EWA13120


2. Remove: Front brake light switch Clutch switch

NOTE:

Release the key by pressing its projection, andremove the handlebar from the master cylinderassembly or clutch lever assembly.

3. Remove: Handlebar grip “1”

NOTE:

Blow compressed air between the handlebarand the handlebar grip, and gradually push thegrip off the handlebar.

EAS22880

CHECKING THE HANDLEBAR1. Check:

HandlebarBends/cracks/damage → Replace.

WARNING

EWA13690

Do not attempt to straighten a bent handle-bar as this may dangerously weaken it.

EAS22921

INSTALLING THE HANDLEBAR1. Stand the vehicle on a level surface.

WARNING

EWA13120


2. Install: Handlebar “1” Upper handlebar holders “2”

CAUTION:

EC3C51009

First, tighten the bolts on the front side of thehandlebar holder, and then on the rear side.

NOTE:

Align mark “a” of the handlebar with the topface of upper bracket.

The upper handlebar holders should be in-stalled with the arrow marks “b” facing forward“A”.

3. Install: Special washer Handlebar grip

a. Slightly coat the handlebar left end with a rub-ber adhesive.

b. Slide the handlebar grip over the left end ofthe handlebar.

Handlebar holder bolt23 Nm (2.3 m•kg, 17 ft•lb)T

R..

22

1

a

A

b

HANDLEBAR

4-37

c. Clean the excessive rubber adhesive with aclean cloth. rubber adhesive

WARNING

EWA13700

Do not touch the handlebar grip until the rub-ber adhesive has fully dried.

1. Install: Left handlebar switch “1”

NOTE:

Align tab “a” of special washer with slot “b” ofleft handlebar switch.

Align the matching surface of left handlebarswitch with mark “c” of the handlebar.

2. Install: Clutch lever assembly “1” Clutch lever holder “2”

NOTE:

Align the mating surfaces of the clutch leverholder with the punch mark “a” on the handlebar.

3. Install: Throttle grip “1” Throttle cables “2” Throttle cable housing “3”

WARNING

EWA13720

Make sure the throttle grip operates smooth-ly.

NOTE:

Align projection “a” of slot cable housing withhole “b” of the handlebar.

Slightly coat the end of slot cable and inside ofthrottle grip with Yamaha Grease B. Then,mount the throttle grip onto the handlebar.

4. Install: Right handlebar switch “1”

NOTE:

Align projection “a” of the right handlebar switchwith hole “b” of the handlebar.

5. Install: Front brake master cylinder assembly “1” Front brake master cylinder holder “2”

NOTE:

Install the brake master cylinder holder with the“UP” mark facing up.

Align the matching surface of brake master cyl-inder holder with mark “a” of handlebar.

Tighten the upper bolt first, and then tightenthe lower bolt.

1

a

b

c

1a

2

Front brake master cylinder as-sembly

7 Nm (0.7 m•kg, 5.1 ft•lb)

b

3

a 12

b a

1

TR..

HANDLEBAR

4-38

6. Adjust: Clutch cable free play

Refer to “ADJUSTING THE CLUTCH CA-BLE FREE PLAY” on page 3-12.


Refer to “ADJUSTING THE THROTTLE CA-BLE FREE PLAY” on page 3-7

Clutch lever free play10.0–15.0 mm (0.39–0.59 in)


a 21

FRONT FORK

4-39

EAS22950

FRONT FORKRemoving the front fork legs


Front wheel Refer to “FRONT WHEEL” on page 4-2.

1 Brake hose holder 1

2 Front brake caliper 1

3 Mudguard 1

4 Upper bracket pinch bolt 2 Loosen.

5 Front fork cap bolt 1 Loosen.

6 Lower bracket pinch bolt 2 Loosen.

7 Fork leg 1

8 Dust boot 1


TR..

23 Nm (2.3 m • kg, 17 ft • Ib)

TR..

40 Nm (4.0 m • kg, 29 ft • Ib)

4

6

8

5

7

12

3

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

23 Nm (2.3 m • kg, 17 ft • Ib)

TR..

23 Nm (2.3 m • kg, 17 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

FRONT FORK

4-40

Disassembling the front fork legs


1 Front fork cap bolt 1

2 Cap bolt O-ring 1

3 Spacer 1

4 Spring seat 1

5 Fork spring 1

6 Dust seal 1

7 Oil seal clip 1

8 Damper rod bolt 1

9 Copper washer 1

10 Inner tube 1

11 Oil seal 1

12 Washer 1

13 Outer tube bushing 1

14 Oil flow stopper 1

15 Spacer 1

16 Spring 1

17 Damper rod 1

18 Rebound spring 1

19 Inner tube bushing 1

20 Outer tube 1

12

3

4

517

18

10

19

16

1514

6

711

12

13

20

9

8

New

New

New

New

New

New

LT

TR..

18 Nm (1.8 m • kg, 13 ft • Ib)

TR..

23 Nm (2.3 m • kg, 17 ft • Ib)

FRONT FORK

4-41


Disassembling the front fork legs


12

3

4

517

18

10

19

16

1514

6

711

12

13

20

9

8

New

New

New

New

New

New

LT

TR..

18 Nm (1.8 m • kg, 13 ft • Ib)

TR..

23 Nm (2.3 m • kg, 17 ft • Ib)

FRONT FORK

4-42

EAS22970

REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the vehicle on a level surface.

WARNING

EWA13120


NOTE:


2. Loosen: Upper bracket pinch bolt “1” Front fork cap bolt “2” Lower bracket pinch bolts “3”

WARNING

EWA13640

Before loosening the upper and lower brack-et pinch bolts, support the front fork leg.

EAS22980

DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Drain:

Fork oilNOTE:

Stroke the outer tube several times while drain-ing the fork oil.

2. Remove: Dust seal “1” Oil seal clip “2”

(with a flat-head screwdriver)

CAUTION:

ECA14180

Do not scratch the inner tube.

3. Remove: Damper rod assembly bolt Copper washer

NOTE:

While holding the damper rod assembly with thedamper rod holder “1” and T-handle “2”, loosenthe damper rod bolt.

1

2

3


FRONT FORK

4-43

4. Remove: Inner tube

a. Hold the front fork leg horizontally.b. Securely clamp the brake caliper bracket in a

vise with soft jaws.c. Separate the inner tube from the outer tube

by pulling the inner tube forcefully but careful-ly.

CAUTION:

ECA14190

Excessive force will damage the oil sealand bushing. A damaged oil seal or bush-ing must be replaced.

Avoid bottoming the inner tube into theouter tube during the above procedure, asthe oil flow stopper will be damaged.

EAS23010

CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check:

Inner tube Outer tube

Bends/damage/scratches → Replace.

WARNING

EWA13650

Do not attempt to straighten a bent innertube as this may dangerously weaken it.

2. Measure: Spring free length “a”

Out of specification → Replace.

3. Check: Damper rod

Damage/wear → Replace.Obstruction → Blow out all of the oil passag-es with compressed air.

Oil flow stopperDamage → Replace.

CAUTION:

ECA14200

The front fork leg has a built-in damper ad-justing rod and a very sophisticated inter-nal construction, which are particularlysensitive to foreign material.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

4. Check: Cap bolt


EAS23020

ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

WARNING

EWA13660

Make sure the oil levels in both front forklegs are equal.

Uneven oil levels can result in poor han-dling and a loss of stability.

Fork spring free length482.0 mm (18.98 in)

Limit472.3 mm (18.59 in)

FRONT FORK

4-44

NOTE:

When assembling the front fork leg, be sure toreplace the following parts: Inner tube bushing Outer tube bushing Oil seal Dust seal

Before assembling the front fork leg, makesure all of the components are clean.

1. Install: Inner tube bushing “1” Damper rod “2” Rebound spring Spring “3” Spacer “4” Oil flow stopper “5”

CAUTION:

EC3C51002

Allow the damper rod assembly to slideslowly down the inner tube “6” until it ap-pears from the bottom of the inner tube. Becareful not to damage the inner tube.

2. Lubricate: Inner tube’s outer surface

3. Tighten: Damper rod bolt “1”

NOTE:

While holding the damper rod assembly with thedamper rod holder “2” and T-handle “3”, tightenthe damper rod assembly bolt.

4. Install: Outer tube bushing “1” Washer “2”

(with the fork seal driver weight “3” and forkseal driver attachment “4”)

5. Install: Oil seal “1”

(with the fork seal driver weight “2” and forkseal driver attachment “3”)

CAUTION:

ECA14220

Make sure the numbered side of the oil sealfaces up.

NOTE:

Before installing the oil seal, lubricate its lipswith lithium soap base grease.

Recommended oilYamaha fork oil 15WT

Damper rod bolt18 Nm (1.8 m•kg, 13 ft•lb)LOCTITE®204Apply locking agent (LOC-TITE®)

New

5

43

6

21

New

TR..


T-handle90890-01326

T-handle 3/8" drive 60 cm longYM-01326

Fork seal driver weight90890-01367

Replacement hammerYM-A9409-7

Fork seal driver attachment (ø35)90890-01369

Replacement 35 mmYM-A9409-5

New

New

FRONT FORK

4-45

Lubricate the outer surface of the inner tubewith fork oil.

Before installing the oil seal, cover the top ofthe front fork leg with a plastic bag to protectthe oil seal during installation.

6. Install: Oil seal clip “1”

NOTE:

Adjust the oil seal clip so that it fits into the outertube’s groove.

7. Install: Dust seal “1”

(with the fork seal driver weight “2”)

8. Fill: Front fork leg

(with the specified amount of the recom-mended fork oil)

NOTE:

While filling the front fork leg, keep it upright. After filling, slowly pump the front fork leg up

and down to distribute the fork oil.

9. Install: Fork spring Spring seat Spacer Front fork cap bolt

NOTE:

Before installing the cap bolt, lubricate itsO-ring with grease.

Temporarily tighten the cap bolt.

Fork seal driver weight90890-01367

Replacement hammerYM-A9409-7

Quantity385.0 cm3 (13.02 US oz) (13.58Imp.oz)

Recommended oilYamaha fork oil 15WT

Level125.0 mm (4.92 in)

At position “a” from the innertube top end when the inner tubeis fully compressed in the outertube

FRONT FORK

4-46

EAS23050

INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install:

Dust boot Clamp screw

(temporarily)2. Install:

Front fork legTemporarily tighten the upper and lowerbracket pinch bolts.

NOTE:

The inner tube top face must match the upperbracket top face.

3. Tighten: Lower bracket pinch bolt “1”

Front fork cap bolt “2”

Upper bracket pinch bolt “3”

WARNING

EWA13680

Make sure the brake hoses are routed prop-erly.

4. Install: Dust boots “1” Clamp screw

NOTE:

Direct air-bleeding hole “a” of the dust boot out-ward of the vehicle, and press and assemble thedust boot top end to the lower bracket.

Lower bracket pinch bolt23 Nm (2.3 m•kg, 17 ft•lb)

Front fork cap bolt23 Nm (2.3 m•kg, 17 ft•lb)

Upper bracket pinch bolt23 Nm (2.3 m•kg, 17 ft•lb)

TR..

TR..

TR..

1

3

2

a

1

STEERING HEAD

4-47

EAS23090

STEERING HEADRemoving the head light unit, meter assembly and front fender


Tool boxRefer to “GENERAL CHASSIS” on page 4-1.

Fuel tank Refer to “FUEL TANK” on page 6-1.

Handlebar Refer to “HANDLEBAR” on page 4-35.

Fork leg Refer to “FRONT FORK” on page 4-39.

1 Head light cowling 1

2 Headlight unit 1

3 Headlight coupler 1 Disconnect.

4 Turn signal light connector 2 Disconnect.

5 Front turn signal light/rear turn signal light 1/1

6 Meter assembly coupler 3 Disconnect.

7 Meter assembly 1


9 Head light unit stay 1

10 Front fender 1

11 Brake hose holder bracket 1


1

4

7

4

5

6

(4)

(4)

2

811

10

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

2 Nm (0.2 m • kg, 1.4 ft • Ib)

3 5

TR..

3 Nm (0.3 m • kg, 2.2 ft • Ib)

9

STEERING HEAD

4-48

Removing the lower bracket


Headlight unit/meter assembly/front fender Refer to “STEERING HEAD” on page 4-47.

1 Main switch coupler 1

2 Steering stem nut 1

3 Upper bracket 1

4 Lock washer 1

5 Upper ring nut 1

6 Rubber washer 1

7 Lower ring nut 1

8 Lower bracket 1

9 Bearing cover 1

10 Washer 1

11 Upper bearing 1

12 Lower bearing 1

13 Bearing races 2


2

3

4

567

910

1113

13

12

8

1

TR..

110 Nm (11 m • kg, 80 ft • Ib)

38 Nm (3.8 m • kg, 28 ft • Ib)

4 Nm (0.4 m • kg, 2.9 ft • Ib)

Return fullyTR.

1st

2nd

STEERING HEAD

4-49

EAS23110

REMOVING THE LOWER BRACKET1. Stand the vehicle on a level surface.

WARNING

EWA13120


2. Remove: Upper ring nut Rubber washer Lower ring nut “1”

NOTE:

Remove both upper and lower ring nuts usingthe ring nut wrench.

WARNING

EWA13730

Securely support the lower bracket so thatthere is no danger of it falling.

EAS23120

CHECKING THE STEERING HEAD1. Wash:

Bearings Bearing races

2. Check: Bearings Bearing races

Damage/pitting → Replace.3. Replace:

Bearings Bearing races

a. Remove the bearing races from the steeringhead pipe with a long rod “1” and hammer.

b. Remove the bearing from the lower bracketwith a floor chisel “2” and hammer.

c. Install new bearing races.

CAUTION:

ECA14270

If the bearing race is not installed properly,the steering head pipe could be damaged.

NOTE:

Always replace the bearings and bearing racesas a set.

4. Check: Upper bracket Lower bracket

(along with the steering stem)Bends/cracks/damage → Replace.

EAS23140

INSTALLING THE STEERING HEAD1. Lubricate:

Upper bearing Lower bearing Bearing races

2. Install: Lower bracket Lower ring nut “1” Rubber washer “2”

Ring nut wrench90890-01268


Recommended cleaning solventKerosene

1


STEERING HEAD

4-50

Upper ring nut “3” Lock washer “4”

Refer to “CHECKING AND ADJUSTINGTHE STEERING HEAD” on page 3-21.

NOTE:

Portion “a” having the large tapered area mustface downward when the lower ring nut ismounted.

3. Install: Upper bracket Steering stem nut

NOTE:

Temporarily tighten the steering stem nut.

4. Install: Front fork legs

Refer to “FRONT FORK” on page 4-39.NOTE:

Temporarily tighten the lower bracket pinchbolts.

5. Tighten: Steering stem nut

Steering stem nut110 Nm (11.0 m•kg, 80 ft•lb)

3

2

1

4

a

TR..

REAR SHOCK ABSORBER ASSEMBLY

4-51

EAS23160

REAR SHOCK ABSORBER ASSEMBLYRemoving the rear shock absorber assembly


Rear left side cover/rear right side coverRefer to “GENERAL CHASSIS” on page 4-1.

1 Connecting arm 2

2 Relay arm 1

3 Rear shock absorber assembly 1

4 Spacer 1

5 Spacer 1

6 Spacer 1

7 Oil seal 6

8 Bearing 1

9 Bushing 3


M

M

M

MM

M

M

TR..

50 Nm (5.0 m • kg, 36 ft • Ib)

TR..

50 Nm (5.0 m • kg, 36 ft • Ib)

13

7

7

6

42 8

7

97

97

159

7

TR..

59 Nm (5.9 m • kg, 43 ft • Ib)

TR..

40 Nm (4.0 m • kg, 29 ft • Ib)


4-52

EAS23180

HANDLING THE REAR SHOCK ABSORBER

WARNING

EWA13740

This rear shock absorber contains highlycompressed nitrogen gas. Before handlingthe rear shock absorber, read and make sureyou understand the following information.The manufacturer cannot be held responsi-ble for property damage or personal injurythat may result from improper handling ofthe rear shock absorber. Do not tamper or attempt to open the rear

shock absorber. Do not subject the rear shock absorber to

an open flame or any other source of highheat. High heat can cause an explosion dueto excessive gas pressure.

Do not deform or damage the rear shockabsorber in any way. Rear shock absorberdamage will result in poor damping perfor-mance.

EAS23190

DISPOSING OF A REAR SHOCK ABSORBER1. Gas pressure must be released before dis-

posing of a rear shock absorber. To releasethe gas pressure, drill a 2–3-mm hole throughthe rear shock absorber at a point 60 mmfrom its end as shown.

WARNING

EWA13760

Wear eye protection to prevent eye damagefrom released gas or metal chips.

EAS23230

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY1. Stand the vehicle on a level surface.

WARNING

EWA13120


NOTE:


EAS23240

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY1. Check:

Rear shock absorber rodBends/damage → Replace the rear shockabsorber assembly.

Rear shock absorberGas leaks/oil leaks → Replace the rear shockabsorber assembly.

SpringDamage/wear → Replace the rear shock ab-sorber assembly.

BushingsDamage/wear → Replace.

BoltsBends/damage/wear → Replace.

EAS23260

CHECKING THE CONNECTING ARM AND RELAY ARM1. Check:

Connecting arms Relay arm

Damage/wear → Replace.2. Check:

Bearings Oil seals Bushing

Damage/pitting → Replace.3. Check:

SpacersDamage/scratches → Replace.

EAS23270

INSTALLING THE RELAY ARM1. Lubricate:

Spacers Bearings Oil seal

2. Install: Bearing “1”

(to the relay arm “2”) Bushing “3”

to relay arm “2”

Recommended lubricantLithium soap base grease


4-53

EAS23310

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY1. Install:

Rear shock absorber assemblyNOTE:

Install the rear shock absorber by facing its valvebackward.

2. Tighten: Rear shock absorber assembly upper nut

Relay arm nut (frame side)

Rear shock absorber assembly lower nut

Connecting arm nut (relay-arm side)

Connecting arm nut (swingarm side)

Installed depth “a”4.5 mm

Installed depth “b”3 mm

Installed depth “c”4 mm

Rear shock absorber assemblyupper nut

50 Nm (5.0 m•kg, 36 ft•lb)

Relay-arm nut (frame side)50 Nm (5.0 m•kg, 36 ft•lb)

Rear shock absorber assemblylower nut

40 Nm (4.0 m•kg, 29 ft•lb)

Connecting arm nut (relay-armside)

59 Nm (5.9 m•kg, 43 ft•lb)

Connecting arm nut (swingarmside)

59 Nm (5.9 m•kg, 43 ft•lb)

a

b

b

c1

2

3

3

3

TR..

TR..

TR..

TR..

TR..

SWINGARM

4-54

EAS23330

SWINGARMRemoving the swingarm



Rear shock absorber assemblyRefer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-51.


2 Pivot shaft nut 1

3 Pivot shaft 1

4 Swingarm 1

5 Front drive chain guide 1

6 Rear drive chain guide 1

7 Dust cover 2

8 Spacer 1

9 Bushing 2

10 Spacer 1

11 Oil seal 2

12 Bushing 2


M

M

M

M

M

LT

TR..

80 Nm (8.0 m • kg, 58 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

2

3

9

5

1 4

6

7

7

11

12

10129

8 11

SWINGARM

4-55

EAS23350

REMOVING THE SWINGARM1. Stand the vehicle on a level surface.

WARNING

EWA13120


NOTE:


2. Measure: Swingarm side play Swingarm vertical movement

a. Measure the tightening torque of the pivotshaft nut.

b. Measure the swingarm side play “A” by mov-ing the swingarm from side to side.

c. If the swingarm side play is out of specifica-tion, check the spacers, bearings, washers,and dust covers.

d. Check the swingarm vertical movement “B”by moving the swingarm up and down.If swingarm vertical movement is not smoothor if there is binding, check the spacers,spacers, washers, and dust covers.

EAS23360

CHECKING THE SWINGARM1. Check:

SwingarmBends/cracks/damage → Replace.

2. Check: Pivot shaft

Roll the pivot shaft on a flat surface.Bends → Replace.

WARNING

EWA13770

Do not attempt to straighten a bent pivotshaft.

3. Wash: Pivot shaft Dust covers Spacer Washers Bushing

4. Check: Dust covers Spacer Washers Oil seals

Damage/wear → Replace. Bushing

Damage/pitting → Replace.

EAS23380

INSTALLING THE SWINGARM1. Lubricate:

Bushing Spacers Dust covers Pivot shaft

2. Install: Bushing “1”

Pivot shaft nut80 Nm (8.0 m•kg, 58 ft•lb)

Swingarm up/down stroke limit atrear end position of the rear arm

1.0 mmSwing arm play limit on the pivotshaft

1.0 mm

TR..

A

B

Recommended cleaning solventKerosene

Recommended lubricantMolybdenum disulfide grease

SWINGARM

4-56

Oil seal “2” Spacer “3”

(to the swingarm “4”)

3. Install: Rear shock absorber assembly Rear wheel

Refer to “REAR SHOCK ABSORBER AS-SEMBLY” on page 4-51 and “REAR WHEEL”on page 4-8.


Refer to “ADJUSTING THE DRIVE CHAINSLACK” on page 3-20.

Installed depth “a”3 mm


a a

2 2

3 4

1

CHAIN DRIVE

4-57

EAS23400

CHAIN DRIVERemoving the drive chain


Swingarm Refer to “SWINGARM” on page 4-54.

1 Drive sprocket cover 1

2 Drive sprocket nut 1

3 Lock washer 1

4 Drive sprocket 1

5 Drive chain 1


32

4

1

5

New

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

110 Nm (11 m • kg, 80 ft • Ib)

CHAIN DRIVE

4-58

EAS23420

REMOVING THE DRIVE CHAIN1. Stand the vehicle on a level surface.

WARNING

EWA13120


NOTE:


2. Remove: Drive sprocket nut “1” Lock washer “2”

NOTE:

Straighten the lock washer tab. Operate the rear brake, and loosen the drive

sprocket. After loosening the drive sprocket, remove the

rear wheel and swingarm.

3. Remove: Swingarm

Refer to “SWINGARM” on page 4-54.

EAS23441

CHECKING THE DRIVE CHAIN1. Measure:

15-link section “a” of the drive chainOut of specification → Replace the drivechain.

a. Measure the length “a” between the innersides of the pins and the length “b” betweenthe outer sides of the pins on a 15-link sectionof the drive chain as shown in the illustration.

b. Calculate the length “c” of the 15-link section,push down on the drive chain to increase itstension.Drive chain 15-link section length “c” =(length “a” between pin inner sides + length“b” between pin outer sides)/2

NOTE:

When measuring a 15-link section of the drivechain, make sure that the drive chain is taut.

Perform this procedure 2–3 times, at a differentlocation each time.

2. Check: Drive chain

Stiffness → Clean, lubricate, or replace.

3. Clean: Drive chain

a. Wipe the drive chain with a clean cloth.

15-link length limit191.5 mm (7.54 in)

1

2

CHAIN DRIVE

4-59

b. Put the drive chain in kerosene and removeany remaining dirt.

c. Remove the drive chain from the keroseneand completely dry it.

CAUTION:

EC3C51003

This vehicle has a drive chain with small rub-ber O-rings “1” between the drive chain sideplates. Steam cleaning, high-pressure wash-ing, certain solvents, and the use of a coarsebrush can damage these O-rings.

4. Check: O-rings “1”

Damage → Replace the drive chain. Drive chain rollers “2”

Damage/wear → Replace the drive chain. Drive chain side plates “3”

Damage/wear → Replace the drive chain.Cracks → Replace the drive chain.

5. Lubricate: Drive chain

EAS23460

CHECKING THE DRIVE SPROCKET1. Check:

Drive sprocketRefer to “CHECKING AND REPLACINGTHE REAR WHEEL SPROCKET” on page4-10.

EAS23490

INSTALLING THE DRIVE CHAIN1. Lubricate:

Drive chain

2. Install: Drive chain Drive sprocket “1” Lock washer “2” Drive sprocket nut “3”

(temporarily)NOTE:

While applying the drive sprocket, tighten thedrive sprocket nut.

3. Install: Swingarm

Refer to “SWINGARM” on page 4-54. Rear wheel

Refer to “REAR WHEEL” on page 4-8.4. Install:

Lock washer “1” Drive sprocket “2”



Drive sprocket nut110 Nm (11.0 m•kg, 80 ft•lb)

New

1

2

3

New

TR..

CHAIN DRIVE

4-60

NOTE:

Tighten the drive sprocket nut by applying therear drive.

Be sure to bend the lock washer tab along tothe nut side face.


Refer to “ADJUSTING THE DRIVE CHAINSLACK” on page 3-20

CAUTION:

ECA13550

A drive chain that is too tight will overloadthe engine and other vital parts, and one thatis too loose can skip and damage the swing-arm or cause an accident. Therefore, keepthe drive chain slack within the specified lim-its.


2

1

1

2

3

4

5

6

7

8

9

ENGINE

ENGINE REMOVAL .......................................................................................5-1INSTALLING THE ENGINE .....................................................................5-4INSTALLING THE SHIFT PEDAL............................................................5-4

CYLINDER HEAD ..........................................................................................5-6REMOVING THE CYLINDER HEAD .......................................................5-8CHECKING THE CYLINDER HEAD........................................................5-9CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER........................................................5-9CHECKING THE CAMSHAFT SPROCKET AND TIMING CHAIN GUIDE (EXHAUST SYSTEM SIDE)............................5-9CHECKING THE TIMING CHAIN TENSIONER ......................................5-10INSTALLING THE CYLINDER HEAD......................................................5-10

CAMSHAFT....................................................................................................5-13REMOVING THE ROCKER ARMS AND CAMSHAFT ............................5-14CHECKING THE CAMSHAFT .................................................................5-14CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS .........5-15INSTALLING THE CAMSHAFT AND ROCKER ARMS...........................5-15

VALVES AND VALVE SPRINGS ..................................................................5-17REMOVING THE VALVES.......................................................................5-18CHECKING THE VALVES AND VALVE GUIDES ...................................5-18CHECKING THE VALVE SEATS.............................................................5-20CHECKING THE VALVE SPRINGS ........................................................5-21INSTALLING THE VALVES .....................................................................5-23

CYLINDER AND PISTON ..............................................................................5-25REMOVING THE PISTON .......................................................................5-26CHECKING THE CYLINDER AND PISTON............................................5-26CHECKING THE PISTON RINGS ...........................................................5-27CHECKING THE PISTON PIN.................................................................5-28INSTALLING THE PISTON AND CYLINDER..........................................5-28

CLUTCH .........................................................................................................5-30REMOVING THE CLUTCH......................................................................5-33CHECKING THE FRICTION PLATES .....................................................5-33CHECKING THE CLUTCH PLATES........................................................5-33CHECKING THE CLUTCH SPRINGS .....................................................5-33CHECKING THE CLUTCH HOUSING.....................................................5-34CHECKING THE CLUTCH BOSS............................................................5-34CHECKING THE PRESSURE PLATE.....................................................5-34CHECKING THE CLUTCH PUSH RODS ................................................5-34CHECKING THE PRIMARY DRIVE GEAR..............................................5-34CHECKING THE PRIMARY DRIVEN GEAR...........................................5-34INSTALLING THE CLUTCH.....................................................................5-34

OIL PUMP AND BALANCER GEAR .............................................................5-38REMOVING THE BALANCER GEAR......................................................5-40CHECKING THE OIL PUMP....................................................................5-40CHECKING THE OIL STRAINER ............................................................5-40ASSEMBLING THE OIL PUMP................................................................5-41INSTALL THE OIL PUMP AND BALANCER GEAR ................................5-41

SHIFT SHAFT ................................................................................................5-43CHECKING THE SHIFT SHAFT..............................................................5-44CHECKING THE STOPPER LEVER .......................................................5-44INSTALLING THE SHIFT SHAFT............................................................5-44

GENERATOR AND STARTER CLUTCH ......................................................5-45REMOVING THE GENERATOR..............................................................5-47REMOVING THE STARTER CLUTCH ....................................................5-47CHECKING THE STARTER CLUTCH.....................................................5-47INSTALLING THE STARTER CLUTCH...................................................5-48INSTALLING THE GENERATOR ............................................................5-48

ELECTRIC STARTER...................................................................................5-50CHECKING THE STARTER MOTOR......................................................5-52ASSEMBLING THE STARTER MOTOR..................................................5-53

CRANKCASE.................................................................................................5-54DISASSEMBLING THE CRANKCASE ....................................................5-56CHECKING THE CRANKCASE...............................................................5-56CHECKING THE TIMING CHAIN, CRANKSHAFT SPROCKET, TIMING CHAIN GUIDE (INTAKE SIDE)..........................5-56CHECKING THE BEARING AND OIL SEAL ...........................................5-56ASSEMBLING THE CRANKCASE ..........................................................5-56

CRANKSHAFT ASSEMBLY..........................................................................5-58REMOVING THE CRANKSHAFT ASSEMBLY........................................5-59CHECKING THE CRANKSHAFT AND CONNECTING ROD..................5-59INSTALLING THE CRANKSHAFT ASSEMBLY ......................................5-59

TRANSMISSION ............................................................................................5-61CHECKING THE SHIFT FORKS .............................................................5-63CHECKING THE SHIFT DRUM ASSEMBLY...........................................5-63CHECKING THE TRANSMISSION..........................................................5-63INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY .......5-64

ENGINE REMOVAL

5-1

EAS23710

ENGINE REMOVALRemoving the exhaust pipe


Rear right side coverRefer to “GENERAL CHASSIS” on page 4-1.

1 Muffler 1

2 Exhaust pipe 1

3 Exhaust pipe gasket 1


New1

2

3 New

TR..

18 Nm (1.8 m • kg, 13 ft • Ib)

TR..

20 Nm (2.0 m • kg, 15 ft • Ib)

TR..

42 Nm (4.2 m • kg, 30 ft • Ib)

TR..

42 Nm (4.2 m • kg, 30 ft • Ib)

ENGINE REMOVAL

5-2

Removing the shift pedal assembly and leads and hoses


Carburetor Refer to “CARBURETOR” on page 6-3.

Drive sprocket Refer to “CHAIN DRIVE” on page 4-57.

Starter motorRefer to “ELECTRIC STARTER” on page 5-50.

1 Cylinder head breather hose 1 Disconnect.

2 Spark plug cap 1 Disconnect.

3 Clutch cable 1 Disconnect.

4 Pickup coil coupler/stator assembly coupler 1/1 Disconnect.

5 Speed sensor coupler 1 Disconnect.

6 Horn 1

7 Shift pedal assembly 1

8 Neutral switch lead 1 Disconnect.


TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

4

8

7

2

1

3

5

6

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

30 Nm (3.0 m • kg, 22 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

ENGINE REMOVAL

5-3

Removing the engine


NOTE:Use an appropriate vehicle stand and support

the engine securely.

Drain the engine oilRefer to “CHANGING THE ENGINE OIL” on page 3-11.

1 Engine mounting bolt (upper side) 1

2 Engine bracket bolt 2

3 Right engine bracket 1

4 Left engine bracket 1

5 Engine mounting bolts (front upper side) 1

6 Engine mounting bolt (front lower side) 1

7 Down tube bolts (front side) 2

8 Down tube bolts (rear side) 1

9 Down tube 1

10 Engine mounting bolt (rear lower side) 1

11 Engine mounting bolt (rear upper side) 1

12 Engine assembly 1

For assembly, reverse the removal proce-dure.

TR..

60 Nm (6.0 m • kg, 43 ft • Ib)

TR..

60 Nm (6.0 m • kg, 43 ft • Ib)

10

12

2

4

3

12

7

9 5

6

8

11

TR..

44 Nm (4.4 m • kg, 32 ft • Ib)

TR..

60 Nm (6.0 m • kg, 43 ft • Ib)

ENGINE REMOVAL

5-4

EAS23720

INSTALLING THE ENGINE1. Install:

Engine assembly “1” Engine mounting bolt (rear upper side)“2” Engine mounting bolt (rear lower side)“3” Down tube “4” Down tube bolt (Rear)“5” Down tube bolt (Front)“6” Engine mounting bolt (front lower side)“7” Engine mounting bolts (front upper side)“8” Left engine bracket “9” Right engine bracket “10” Engine bracket bolt “11” Engine mounting bolt (upper side)“12”

NOTE:

The bolts and nuts must be tightened temporari-ly in this stage.(Temporarily tighten)

2. Tighten: Engine mounting nut (rear upper)

Engine mounting nut (rear lower)

Down tube nut (rear)

Down tube nut (front)

Engine mounting nut (front upper)

Engine mounting nut (front upper)

Engine bracket nut

Engine mounting nut (upper)

EAS3C51004

INSTALLING THE SHIFT PEDAL1. Install:

Shift pedal assembly “1”

NOTE:

Align mark “a” of the shift shaft with mark “b” ofthe shift arm.

2. Adjust: Shift pedal position

NOTE:

Loosen the lock nut “1” and turn shift rod “2” sothat height “a” from the footrest to the shift pedaltop face comes within 16 to 22 mm (0.63 to 0.79

Engine mounting nut (rear upper)60 Nm (6.0 m•kg, 43 ft•lb)

Engine mounting nut (rear lower)60 Nm (6.0 m•kg, 43 ft•lb)

Down tube nut (rear)60 Nm (6.0 m•kg, 43 ft•lb)

3

12

11

119

10

1

6

4 8

7

5

2

TR..

TR..

TR..

Down tube nut (front)60 Nm (6.0 m•kg, 43 ft•lb)

Engine mounting nut (front up-per)

60 Nm (6.0 m•kg, 43 ft•lb)

Engine mounting nut (front up-per)

60 Nm (6.0 m•kg, 43 ft•lb)

Engine bracket nut44 Nm (4.0 m•kg, 32 ft•lb)

Engine mounting nut (upper)60 Nm (6.0 m•kg, 43 ft•lb)

Shift pedal bolt30 Nm (3.0 m•kg, 22 ft•lb)

Shift arm bolt10 Nm (1.0 m•kg, 7.2 ft•lb)

TR..

TR..

TR..

TR..

TR..

TR..

a

b

1

ENGINE REMOVAL

5-5

in). When this adjustment is complete, tightenthe locknut “1”.

Locknut10 Nm (1.0 m•kg, 7.2 ft•lb)T

R..

21 1

a

CYLINDER HEAD

5-6

EAS24100

CYLINDER HEADRemoving the cylinder head


Tool boxRefer to “GENERAL CHASSIS” on page 4-1.


Left engine bracket/Right engine bracket Refer to “ENGINE REMOVAL” on page 5-1.

1 Spark plug 1

2 Timing mark accessing screw 1

3 Crankshaft end cover 1

4 Camshaft sprocket cover 1

5 Breather plate 1

6 Breather plate gasket 1

7 Intake tappet cover 1

8 Exhaust tappet cover 1

9 Camshaft sprocket bolt 1

10 Timing chain tensioner 1

11 Timing chain tensioner gasket 1

12 Camshaft sprocket plate 1

13 Camshaft sprocket 1

14 Dowel pin 1

15 Intake manifold 1

New

New

New

New

New

New

New

New

New

New

New

4

15

7

12

13

56

14

18

19

16

1

1720

2021

8

9

New

10

11

2

3

(4)

M

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

60 Nm (6.0 m • kg, 43 ft • Ib)

TR..

18 Nm (1.8 m • kg, 13 ft • Ib)

TR..

20 Nm (2.0 m • kg, 15 ft • Ib)T

R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

18 Nm (1.8 m • kg, 13 ft • Ib)T

R..

22 Nm (2.2 m • kg, 16 ft • Ib)T

R..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

18 Nm (1.8 m • kg, 13 ft • Ib)T

R..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

LTLT

E

CYLINDER HEAD

5-7

16 Air induction system pipe 1

17 Air induction system pipe gasket 1

18 Cylinder head 1

19 Cylinder head gasket 1

20 Dowel pin 2

21 Timing chain guide (exhaust side) 1


Removing the cylinder head


New

New

New

New

New

New

New

New

New

New

New

4

15

7

12

13

56

14

18

19

16

1

1720

2021

8

9

New

10

11

2

3

(4)

M

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

60 Nm (6.0 m • kg, 43 ft • Ib)

TR..

18 Nm (1.8 m • kg, 13 ft • Ib)

TR..

20 Nm (2.0 m • kg, 15 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

18 Nm (1.8 m • kg, 13 ft • Ib)

TR..

22 Nm (2.2 m • kg, 16 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

18 Nm (1.8 m • kg, 13 ft • Ib)

TR..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

LTLT

E

CYLINDER HEAD

5-8

EAS24130

REMOVING THE CYLINDER HEAD1. Disconnect:

Wire harnessNOTE:

Disconnect the wire harness from the T-stud ofvehicle frame.

2. Align: Mark “a” of the camshaft sprocket

(with mark “b” of the cylinder head)

a. Turn the crankshaft counterclockwise.b. When the piston is in the compression stroke,

align camshaft sprocket mark “a” with cylin-der head mark “b”. (Compression strokeTDC)

NOTE:

Make sure that generator rotor mark “c” alignswith generator rotor cover mark “d”.

3. Loosen: Camshaft sprocket bolt

NOTE:

Tighten the generator rotor bolts but loosen thecamshaft sprocket bolts using a wrench.

4. Remove: Timing chain tensioner

(along with the gasket) Camshaft sprocket plate Camshaft sprocket

NOTE:

To prevent the timing chain from falling into thecrankcase, fasten it with a wire.

5. Remove: Cylinder head

NOTE:

Loosen the cylinder head bolts in the correctsequence as shown.

Loosen each cylinder head bolt for a half turnat a time. When all cylinder head bolts are fullyloosened, remove them.

CYLINDER HEAD

5-9

EAS24160

CHECKING THE CYLINDER HEAD1. Eliminate:

Combustion chamber carbon deposits(with a rounded scraper)

NOTE:

Do not use a sharp instrument to avoid damag-ing or scratching: Spark plug bore threads Valve seats

2. Check: Cylinder head

Damage/scratches → Replace.3. Measure:

Cylinder head warpageOut of specification → Resurface the cylinderhead.

a. Place a straightedge “1” and a thicknessgauge “2” across the cylinder head.

b. Measure the warpage.c. If the limit is exceeded, resurface the cylinder

head as follows.d. Place a 400–600 grit wet sandpaper on the

surface plate and resurface the cylinder headusing a figure-eight sanding pattern.

NOTE:

To ensure an even surface, turn the cylinder

head several times.

e. When the cylinder head warpage is out ofspecification after resurfacing, replace thecylinder head.

EAS23940

CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVERThe following procedure applies to both of thetappet covers and O-rings.1. Check:

Tappet cover Camshaft sprocket cover

EAS3C51005

CHECKING THE CAMSHAFT SPROCKET AND TIMING CHAIN GUIDE (EXHAUST SYSTEM SIDE)Check the camshaft sprocket and the timingchain guide (exhaust system side) as follows.1. Check:

Camshaft sprocketWear of 1/4 or more teeth “a” → Replace thecamshaft sprocket as a set, timing chain, andcrankshaft sprocket.


4

5

6

2

1

3

a. 1/4 tooth wear

b. Normal

1. Timing chain

2. Camshaft sprocket

1

2

a

b

1

2

CYLINDER HEAD

5-10

2. Check: Timing chain guide (exhaust side)

Crack/wear → Replace.

EAS24200

CHECKING THE TIMING CHAIN TENSIONER1. Check:

Timing chain tensionerCracks/damage/rough movement → Re-place.

a. Lightly press the timing chain tensioner rodinto the timing chain tensioner housing byhand.

NOTE:

While pressing the timing chain tensioner rod,wind it clockwise with a thin screwdriver “1” untilit stops.

b. Remove the screwdriver and slowly releasethe timing chain tensioner rod.

c. Make sure that the timing chain tensioner rodcomes out of the timing chain tensioner hous-ing smoothly. If there is rough movement, re-place the timing chain tensioner.

EAS24230

INSTALLING THE CYLINDER HEAD1. Install:

Cylinder head Cylinder head bolts (226 mm) Cylinder head bolts (45 mm)

NOTE:

Apply an engine oil to the seating face of cylin-der head bolt (226-mm long), and apply a mo-lybdenum disulfide oil to the bolt threads.

Tighten the cylinder head bolts in two stages inthe correct sequence as shown.

2. Install: Dowel pin Camshaft sprocket Timing chain

a. Make sure that generator rotor mark “a”aligns with generator rotor cover mark “b”. Ifnot, align them by turning the crankshaftcounterclockwise.

b. Align camshaft sprocket mark “c” with cylin-der head mark “d”.

c. Install the timing chain onto the camshaftsprocket, and then install the camshaftsprocket onto the camshaft.

NOTE:

When installing the camshaft sprocket, be sureto keep the timing chain as tight as possible onthe exhaust side.

Align the dowel pin with the slot of camshaftsprocket.

Assemble the camshaft sprocket by facing itsdie stamp outward of the vehicle.

CAUTION:

ECA13770

Do not turn the crankshaft when installingthe camshaft sprockets to avoid damage orimproper valve.

Cylinder head bolt (226 mm)22 Nm (2.2 m•kg, 16 ft•lb)

Cylinder head bolt (45 mm)20 Nm (2.0 m•kg, 15 ft•lb)

1

TR..

2

3

4

5

6

1

CYLINDER HEAD

5-11

d. While holding the camshafts, temporarilytighten the camshaft sprocket bolts.

e. Remove the wire from the timing chain.

3. Install: Timing chain tensioner

a. Push down the timing chain tensioner rodend by your finger, and fully wind up thetensioner clockwise using a small flat-bladescrewdriver “1” .

NOTE:

The timing chain tensioner rod must be held bythe flat-blade screwdriver until the timing chaintensioner bolt is tightened.

b. Assemble the timing chain tensioner and thegasket in the cylinder.

c. Install the gasket and timing chain tensionercap bolt.

4. Tighten: Camshaft sprocket bolts

CAUTION:

ECA13750

Be sure to tighten the camshaft sprocketbolts to the specified torque to avoid thepossibility of the bolts coming loose anddamaging the engine.

NOTE:

Secure the generator rotor bolts and tighten thecamshaft sprocket bolts using a wrench.

5. Turn: Crankshaft

(several turns counterclockwise)6. Check:

Mark “a”Make sure that generator rotor mark “a”aligns with generator rotor cover mark “b”.

Mark “c”Make sure that camshaft sprocket mark “c”aligns with cylinder head mark “d”.Not aligned → Reassemble.See the following assembling procedure.

Timing chain tensioner bolt10 Nm (1.0 m•kg, 7.2 ft•lb)

Timing chain tensioner cap bolt8 Nm (0.8 m•kg, 5.8 ft•lb)

1T

R..

TR..

Camshaft sprocket bolt60 Nm (6.0 m•kg, 43 ft•lb)T

R..

CYLINDER HEAD

5-12

7. Measure: Bulb clearance

Out of specification → Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE” on page 3-5.

CAMSHAFT

5-13

EAS3C51006

CAMSHAFTREMOVING THE ROCKER ARMS AND CAMSHAFT

Order Job/Part Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-6.

1 Camshaft retainer 1

2 Camshaft 1

3 Intake rocker arm shaft 1

4 Rocker arm 2

5 Exhaust rocker arm shaft 1

6 Locknut 2

7 Valve clearance adjusting screws 2


CAMSHAFT

5-14

EAS23770

REMOVING THE ROCKER ARMS AND CAMSHAFT1. Loosen:

Locknuts “1” Valve clearance adjusting screws “2”

2. Remove: Camshaft retainer “3”

3. Remove: Camshaft “1”

NOTE:

Screw 10-mm bolt “2” into the threaded end ofthe camshaft and then pull out the camshaft.

Take care not to interfere and damage therocker arm.

4. Remove: Intake rocker arm shaft Exhaust rocker arm shaft Rocker arm (Intake and exhaust sides)

NOTE:

Remove the rocker arm using the weight “1” andslide hammer bolt “2”.

EAS23840

CHECKING THE CAMSHAFT1. Check:

Camshaft lobesBlue discoloration/pitting/scratches → Re-place the camshaft.

2. Measure: Camshaft lobe dimensions “a” and “b”

Out of specification → Replace the camshaft.

Slide hammer bolt90890-01083

Slide hammer bolt 6 mmYU-01083-1

Weight90890-01084YU-01083-3

Camshaft lobe dimension limitIntake A

36.520–36.620 mm (1.4378–1.4417 in)

Limit36.460 mm (1.4354 in)

Intake B30.201–30.301 mm (1.1890–1.1930 in)

Limit30.151 mm (1.1870 in)

Exhaust A36.564–36.664 mm (1.4395–1.4435 in)

Limit36.514 mm (1.4376 in)

Exhaust B30.216–30.316 mm (1.1896–1.1935 in)

Limit30.166 mm (1.1876 in)

CAMSHAFT

5-15

3. Check: Camshaft oil passage

Obstruction → Blow out with compressed air.

EAS23880

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTSThe following procedure applies to all of therocker arms and rocker arm shafts.1. Check:

Rocker armDamage/wear → Replace.

2. Check: Rocker arm shaft

Blue discoloration/excessive wear/pitting/scratches → Replace or check the lubricationsystem.

3. Measure: Rocker arm inside diameter “a”


4. Measure: Rocker arm shaft outside diameter “a”


5. Calculate: Rocker-arm-to-rocker-arm-shaft clearance

NOTE:

Calculate the clearance by subtracting the rock-er arm shaft outside diameter from the rockerarm inside diameter.

Out of specification → Replace the defectivepart(s).

EAS24040

INSTALLING THE CAMSHAFT AND ROCKER ARMS1. Lubricate:

Rocker arm Rocker arm shafts

2. Install: Exhaust rocker arm “1” Exhaust rocker arm shaft “2”

NOTE:

The exhaust rocker arm shaft must be insertedinto the cylinder head completely.

Rocker arm inside diameter12.000–12.018 mm (0.4724–0.4731 in)

Limit12.036 mm (0.4739 in)

Rocker arm shaft outside diame-ter

11.981–11.991 mm (0.4717–0.4721 in)

Limit11.950 mm (0.4705 in)

Rocker-arm-to-rocker-arm-shaftclearance

0.009–0.037 mm (0.0004–0.0015in)

Recommended lubricantRocker arm

Molybdenum-disulfide oilRocker arm shaft

Engine oil

CAMSHAFT

5-16

3. Install: Intake rocker arm Intake rocker arm shaft

NOTE:

Insert cylinder head bolt “1” (226-mm long) intothe cylinder head bolt hole.

Keep slot “a” of intake rocker arm shaft in hor-izontal direction, align slot “b” of the shaft endwith the cylinder head bolt hole, and assemblethe camshaft.

4. Lubricate: Camshaft

5. Install: Camshaft

NOTE:

Assemble the camshaft by inserting the 10-mmbolt into the camshaft hole and tightening it.

Recommended lubricantCamshaft

Molybdenum-disulfide oilCamshaft bearing

Engine oil

1

a

b

VALVES AND VALVE SPRINGS

5-17

EAS24270

VALVES AND VALVE SPRINGSRemoving the valves and valve springs



Rocker arm/Camshaft Refer to “CAMSHAFT” on page 5-13.

1 Valve cotter 4

2 Valve spring retainer 2

3 Outer valve spring 2

4 Inner valve spring 2

5 Intake valve 1

6 Exhaust valve 1

7 Valve stem seal 2

8 Valve spring seat 2

9 Valve guide 2



5-18

EAS24280

REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.NOTE:

Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure the valves properly seal.

1. Check: Valve sealing

Leakage at the valve seat → Check the valveface, valve seat, and valve seat width.Refer to “CHECKING THE VALVE SEATS”on page 5-20.

a. Pour a clean solvent “a” into the intake andexhaust ports.

b. Check that the valves properly seal.NOTE:

There should be no leakage at the valve seat“1”.

2. Remove: Valve cotters “1”

NOTE:

Remove the valve cotters by compressing thevalve spring with the valve spring compressor“2”.

3. Remove: Valve spring retainer “1” Outer valve spring “2” Inner valve spring “3” Valve “4” Valve stem seal “5” Valve spring seat “6”

NOTE:

Identify the position of each part very carefullyso that it can be reinstalled in its original place.

EAS24290

CHECKING THE VALVES AND VALVE GUIDESThe following procedure applies to all of thevalves and valve guides.1. Measure:

Valve-stem-to-valve-guide clearanceOut of specification → Replace the valveguide.


Valve-stem-to-valve-guide clearance =Valve guide inside diameter “a” -Valve stem diameter “b”


5-19

2. Replace: Valve guide

NOTE:

To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100°C (212°F) in an oven.

a. Remove the valve guide with the valve guideremover “1”.

b. Install the new valve guide with the valveguide installer “2” and valve guide remover“1”.

c. After installing the valve guide, bore the valveguide with the valve guide reamer “3” to ob-tain the proper valve-stem-to-valve-guideclearance.

NOTE:

After replacing the valve guide, reface the valveseat.

Valve-stem-to-valve-guide clear-ance

Valve-stem-to-valve-guide clear-ance (intake)

0.010–0.037 mm (0.0004–0.0015in)

Limit0.080 mm (0.0032 in)

Valve-stem-to-valve-guide clear-ance (exhaust)

0.025–0.052 mm (0.0010–0.0020in)

Limit0.100 mm (0.0039 in)


5-20

3. Eliminate: Carbon deposits

(from the valve face and valve seat)4. Check:

Valve facePitting/wear → Grind the valve face.

Valve stem endMushroom shape or diameter larger than thebody of the valve stem → Replace the valve.

5. Measure: Valve margin thickness “a”

Out of specification → Replace the valve.

6. Measure: Valve stem runout

Out of specification → Replace the valve.NOTE:

When installing a new valve, always replacethe valve guide.

If the valve is removed or replaced, always re-place the oil seal.

EAS24300

CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Eliminate:

Carbon deposits(from the valve face and valve seat)

2. Check: Valve seat

Pitting/wear → Replace the cylinder head.3. Measure:

Valve seat width “a”Out of specification → Replace the cylinderhead.

a. Apply Mechanic’s blueing dye (Dykem) “b”onto the valve face.

Valve guide remover (ø6)90890-04064

Valve guide remover (6.0 mm)YM-04064-A

Valve guide installer (ø6)90890-04065

Valve guide installer (6.0 mm)YM-04065-A

Valve guide reamer (ø6)90890-04066

Valve guide reamer (6.0 mm)YM-04066

Valve margin thicknessValve margin thickness D (intake)

0.80–1.20 mm (0.0315–0.0472 in)Valve margin thickness D (ex-haust)

0.80–1.20 mm (0.0315–0.0472 in)

Valve stem runoutValve stem runout

0.030 mm (0.0012 in)

Limit of valve seat width (IN)1.7 mm

Limit of valve seat width (EX)1.7 mm


5-21

b. Install the valve into the cylinder head.c. Press the valve through the valve guide and

onto the valve seat to make a clear impres-sion.

d. Measure the valve seat width.NOTE:

Where the valve seat and valve face contactedone another, the blueing will have been re-moved.

4. Lap: Valve face Valve seat

NOTE:

After replacing the cylinder head or replacing thevalve and valve guide, the valve seat and valveface should be lapped.

a. Apply a coarse lapping compound “a” to thevalve face.

CAUTION:

ECA13790

Do not let the lapping compound enter thegap between the valve stem and the valveguide.

b. Apply molybdenum disulfide oil onto thevalve stem.

c. Install the valve into the cylinder head.d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all ofthe lapping compound.

NOTE:

For the best lapping results, lightly tap the valveseat while turning the valve back and forth be-tween your hands.

e. Apply a fine lapping compound to the valveface and repeat the above steps.

f. After every lapping procedure, be sure toclean off all of the lapping compound from thevalve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem) “b”onto the valve face.

h. Install the valve into the cylinder head.i. Press the valve through the valve guide and

onto the valve seat to make a clear impres-sion.

j. Measure the valve seat width “c” again. If thevalve seat width is out of specification, refaceand lap the valve seat.

EAS24310

CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure:

Valve spring free length “a”Out of specification → Replace the valvespring.


5-22

2. Measure: Compressed valve spring force “1”

Out of specification → Replace the valvespring. 3. Measure:

Valve spring tilt “a”Out of specification → Replace the valvespring.

Valve spring free lengthInner springFree length (intake)

36.17 mm (1.42 in)Free length (exhaust)

36.17 mm (1.42 in)Outer springFree length (intake)

36.63 mm (1.44 in)Free length (exhaust)

36.63 mm (1.44 in)

a. Compressed valve spring force

b. Installed length

Inner springInstalled compression springforce (intake)

75.00–91.70 N (16.86–20.61 lbf)(7.65–9.35 kgf)

Installed length (intake)30.50 mm (1.20 in)

Installed compression springforce (exhaust)

75.00–91.70 N (16.86–20.61 lbf)(7.65–9.35 kgf)

Installed length (exhaust)30.50 mm (1.20 in)

Outer springInstalled compression springforce (intake)

128.50–157.90 N (28.89–35.50lbf) (13.10–16.10 kgf)

Installed length (intake)32.00 mm (1.26 in)

Installed compression springforce (exhaust)

128.50–157.90 N (28.89–35.50lbf) (13.10–16.10 kgf)

Installed length (exhaust)32.00 mm (1.26 in)

Spring tilt limitInner springSpring tilt (intake)

2.5 °/1.6 mmSpring tilt (exhaust)

2.5 °/1.6 mmOuter springSpring tilt (intake)

2.5 °/1.6 mmSpring tilt (exhaust)

2.5 °/1.6 mm


5-23

EAS24340

INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:

Valve stem end(with an oil stone)

2. Lubricate: Valve stem “1” Valve stem seal “2”

(with the recommended lubricant)

3. Install: Valve spring seat “1” Valve stem seal “2” Valve “3” Inner valve spring “4” Outer valve spring “5” Valve spring retainer “6”

(on to the cylinder cylinder head)NOTE:

Make sure each valve is installed in its originalplace. Refer to the following embossed marks.

Intake valve: “5HO:”Exhaust valve: “5BP” Install the valve springs with the larger pitch “a”

facing up.

4. Install: Valve cotters “1”

NOTE:

Install the valve cotters by compressing thevalve spring with the valve spring compressor“2”.

5. To secure the valve cotters onto the valvestem, lightly tap the valve tip with a soft-facehammer.

CAUTION:

ECA13800

Hitting the valve tip with excessive forcecould damage the valve.

Recommended lubricantMolybdenum disulfide oil

New

a. Larger pitch

b. Smaller pitch



5-24

CYLINDER AND PISTON

5-25

EAS24350

CYLINDER AND PISTONRemoving the cylinder and piston



1 Cylinder 1

2 Dowel pin 2

3 Cylinder gasket 1

4 Oil delivery pipe 1

5 Piston pin clip 2

6 Piston pin 1

7 Piston 1

8 Top ring 1

9 2nd ring 1

10 Upper oil ring rail 1

11 Lower oil ring rail 1

12 Oil ring expander 1


New

New

New

NewNew

7

8

565

New

2

2

3

4

19

101211

E

E

E

E

TR..

17 Nm (1.7 m • kg, 12 ft • Ib)

TR..

20 Nm (2.0 m • kg, 15 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

CYLINDER AND PISTON

5-26

EAS24380

REMOVING THE PISTON1. Remove:

Piston pin clips “1” Piston pin “2” Piston “3”

CAUTION:

ECA13810

Do not use a hammer to drive the piston pinout.

NOTE:

Before removing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe piston pin clip from falling into the crank-case.

Before removing the piston pin, deburr the pis-ton pin clip’s groove and the piston’s pin borearea.

2. Remove: Top ring 2nd ring Oil ring

NOTE:

When removing a piston ring, open the end gapwith your fingers and lift the other side of the ringover the piston crown.

EAS24390

CHECKING THE CYLINDER AND PISTON1. Check:

Piston wall Cylinder wall

Vertical scratches → Rebore or replace thecylinder, and replace the piston and pistonrings as a set.

2. Measure: Piston-to-cylinder clearance

a. Measure cylinder bore “C” with the cylinderbore gauge.

NOTE:

Measure cylinder bore “C” by taking side-to-sideand front-to-back measurements of the cylinder.Then, find the average of the measurements.

b. If out of specification, rebore or replace thecylinder, and replace the piston and pistonrings as a set.

c. Measure piston skirt diameter D “a” with themicrometer.

Bore74.000–74.0µ16 mm (2.9134–2.9140 in)


Taper limit0.050 mm (0.0020 in)

Out of round limit0.010 mm (0.0004 in)

“C” = maximum of D1–D2

“T” = maximum of D1 or D2 - maximum of D5 orD6

“R” = maximum of D1, D3 or D5 - maximum ofD2, D4 or D6

CYLINDER AND PISTON

5-27

d. If out of specification, replace the piston andpiston rings as a set.

e. Calculate the piston-to-cylinder clearancewith the following formula.

f. If out of specification, rebore or replace thecylinder, and replace the piston and pistonrings as a set.

EAS24430

CHECKING THE PISTON RINGS1. Measure:

Piston ring side clearanceOut of specification → Replace the pistonand piston rings as a set.

NOTE:

Before measuring the piston ring side clearance,eliminate any carbon deposits from the pistonring grooves and piston rings.

2. Install: Piston ring

(into the cylinder)NOTE:

Level the piston ring into the cylinder with thepiston crown.

3. Measure: Piston ring end gap

Out of specification → Replace the pistonring.

NOTE:

The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.

a. Piston skirt diameter

b. 11 mm (0.43 in) from the bottom edge of the pis-ton

Diameter D73.983–73.998 mm (2.9127–2.9133 in)

Piston-to-cylinder clearance =Cylinder bore “C” -Piston skirt diameter “D”

Piston-to-cylinder clearance0.010–0.025 mm (0.0004–0.0010in)

Limit0.15 mm (0.0059 in)

Piston ring side clearanceTop ringRing side clearance

0.030–0.065 mm (0.0012–0.0026in)

Limit0.115 mm (0.0045 in)

2nd ringRing side clearance

0.020–0.055 mm (0.0008–0.0022in)

Limit0.115 mm (0.0045 in)

a. 40 mm (1.57 in)

CYLINDER AND PISTON

5-28

EAS24440

CHECKING THE PISTON PIN1. Check:

Piston pinBlue discoloration/grooves → Replace thepiston pin and then check the lubrication sys-tem.

2. Measure: Piston pin outside diameter “a”

Out of specification → Replace the piston pin.

3. Measure: Piston pin bore diameter “b”

Out of specification → Replace the piston.

4. Calculate: Piston-pin-to-piston-pin-bore clearance

Out of specification → Replace the piston pinand piston as a set.

EAS24450

INSTALLING THE PISTON AND CYLINDER1. Install:

Top ring “1” 2nd ring “2” Lower oil ring rail “3” Upper oil ring rail “4” Oil ring expander “5”

NOTE:

Be sure to install the top ring and 2nd ring so thatthe manufacturer’s marks or numbers face up.

2. Install: Piston “1” Piston pin “2” Piston pin clips “3”

NOTE:

Apply engine oil to the piston pin.

Piston ring end gapTop ringEnd gap (installed)

0.19–0.31 mm (0.0075–0.0122 in)Limit

0.60 mm (0.0236 in)2nd ringEnd gap (installed)

0.30–0.45 mm (0.0118–0.0177 in)Limit

0.60 mm (0.0236 in)Oil ringEnd gap (installed)

0.10–0.35 mm (0.0039–0.0138 in)

Piston pin outside diameter15.991–16.000 mm (0.6296–0.6299 in)

Limit15.971 mm (0.6288 in)

Piston pin bore inside diameter16.002–16.013 mm (0.6300–0.6304 in)

Limit16.043 mm (0.6316 in)

Piston-pin-to-piston-pin-bore clearance=Piston pin bore diameter “b” -Piston pin outside diameter “a”

Piston-pin-to-piston-pin-boreclearance

0.002–0.022 mm (0.0001–0.0009in)

New

CYLINDER AND PISTON

5-29

Make sure the arrow mark “a” on the pistonpoints towards the exhaust side of the cylinder.

Before installing the piston pin clip, cover thecrankcase opening with a clean rag to preventthe clip from falling into the crankcase.

3. Lubricate: Piston Piston rings Cylinder


4. Offset: Piston ring end gaps

5. Install: Cylinder

NOTE:

While compressing the piston rings with onehand, install the cylinder with the other hand.

Pass the timing chain and timing chain guide

(exhaust side) through the timing chain cavity.

Recommended lubricantEngine oil

a. Top ring

b. Upper oil ring rail

c. Oil ring expander

d. Lower oil ring rail

e. 2nd ring

f. 20 mm (0.79 in)

Cylinder bolt10 Nm (1.0 m•kg, 7.2 ft•lb)T

R..

CLUTCH

5-30

EAS25061

CLUTCHRemoving the clutch cover


Drain the engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-11.

Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1.

1 Cotter pin 1

2 Brake pedal 1

3 Oil filter element cover 1

4 Oil filter element 1

5 Oil delivery pipe 1 Disconnect.

6 Clutch cover 1

7 Clutch cover gasket 1

8 Dowel pin 2

9 Gasket 1


New

New

New

New

New

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

30 Nm (3.0 m • kg, 22 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

20 Nm (2.0 m • kg, 15 ft • Ib)

1

2

7

6

5

8

3

4

89

New

CLUTCH

5-31

Removing the clutch


1 Clutch spring 5

2 Pressure plate 1

3 Adjusting screw 1

4 Push plate 1

5 Friction plate 6

6 Clutch plate 5

7 Clutch damper spring 1

8 Clutch damper spring seat 1

9 Primary drive gear nut 1

10 Lock washer 1

11 Claw washer 1

12 Clutch boss nut 1

13 Lock washer 1

14 Clutch boss 1

15 Thrust washer 1

16 Clutch housing 1

17 Ball 1

18 Clutch push rod 1

19 Primary drive gear 1


New

New

E

TR..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

TR..

75 Nm (7.5 m • kg, 54 ft • Ib)

TR..

80 Nm (8.0 m • kg, 58 ft • Ib)

1

2

56

78

12

13

15

1617

910

1119

18

14

34

(5)

CLUTCH

5-32

Removing the push lever shaft


Air cut-off valveRefer to “AIR INDUCTION SYSTEM” on page 6-9.

Generator rotor coverRefer to “GENERATOR AND STARTER CLUTCH” on page 5-45.

1 Clutch cable 1

2 Ignition coil 1

3 Push lever shaft 1

4 Push lever spring 1

5 Circlip 1

6 Oil seal 1

7 Bearing 1


New

New

E

E

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

12 Nm (1.2 m • kg, 8.7 ft • Ib)

1

2

3

4

567

CLUTCH

5-33

EAS25070

REMOVING THE CLUTCH1. Straighten the lock washer tab.2. Loosen:

Primary drive gear nut “1”NOTE:

Insert aluminum plate “a” between primary drivegear “2” and primary driven gear “3”, and loosenthe primary drive gear nut.

3. Loosen: Clutch boss nut “1”

NOTE:

While holding the clutch boss “3” with the univer-sal clutch holder “2”, loosen the clutch boss nut.

EAS25100

CHECKING THE FRICTION PLATESThe following procedure applies to all of the fric-tion plates.1. Check:

Friction plateDamage/wear → Replace the friction platesas a set.

2. Measure: Friction plate thickness

Out of specification → Replace the frictionplates as a set.

NOTE:

Measure the friction plate at four places.

EAS25110

CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check:

Clutch plateDamage → Replace the clutch plates as aset.

2. Measure: Clutch plate warpage

(with a surface plate and thickness gauge “1”)Out of specification → Replace the clutchplates as a set.

EAS25140

CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of theclutch springs.1. Check:

Clutch springDamage → Replace the clutch springs as aset.

2. Measure:


2

1 3

Friction plate thickness2.70–2.90 mm (0.106–0.114 in)



CLUTCH

5-34

Clutch spring free length “a”Out of specification → Replace the clutchsprings as a set.

EAS25150

CHECKING THE CLUTCH HOUSING1. Check:

Clutch housing dogsDamage/pitting/wear → Deburr the clutchhousing dogs or replace the clutch housing.

NOTE:

Pitting on the clutch housing dogs will cause er-ratic clutch operation.

EAS25160

CHECKING THE CLUTCH BOSS1. Check:

Clutch boss splinesDamage/pitting/wear → Replace the clutchboss.

NOTE:

Pitting on the clutch boss splines will cause er-ratic clutch operation.

EAS25170

CHECKING THE PRESSURE PLATE1. Check:

Pressure plateCracks/damage → Replace.

EAS25190

CHECKING THE CLUTCH PUSH RODS1. Check:

Clutch push rod Adjusting screw Ball

Cracks/damage/wear → Replace the defec-tive part(s).

2. Measure: Push rod bending limit


EAS25200

CHECKING THE PRIMARY DRIVE GEAR1. Check:

Primary drive gearDamage/wear → Replace the primary driveand primary driven gears as a set.Excessive noise during operation → Replacethe primary drive and primary driven gears asa set.

EAS25210

CHECKING THE PRIMARY DRIVEN GEAR1. Check:

Primary driven gearDamage/wear → Replace the primary driveand primary driven gears as a set.Excessive noise during operation → Replacethe primary drive and primary driven gears asa set.

EAS25260

INSTALLING THE CLUTCH1. Install:

Primary drive gear “1”

Clutch spring free length40.10 mm (1.58 in)

Limit38.10 mm (1.50 in)

Push rod bending limit0.500 mm (0.0197 in)

CLUTCH

5-35

Clutch housing “2” Thrust washer Clutch boss “3” Lock washer “4” Claw washer “5” Lock washer “6”

NOTE:

Assemble the primary drive gear by facing itsflat face “a” toward the crankcase.

Align lock washer projection “b” with the clutchboss slit during assembling.

Align lock washer projection “c” with the clawwasher slit during assembling.

2. Install: Clutch boss nut Primary drive gear nut

3. Tighten: Clutch boss nut “1”

NOTE:

While holding the clutch boss “3” with the univer-sal clutch holder “2”, tighten the clutch boss nut.

4. Tighten: Primary drive gear nut “1”

NOTE:

Insert aluminum plate “a” between primary drivegear “2” and primary driven gear “3”, and tightenthe primary drive gear nut.

5. Be sure to bend the lock washer tab along tothe nut side face.

6. Lubricate: Friction plates Clutch plates


7. Install: Clutch damper spring seat “1” Clutch damper spring “2” Friction plates Clutch plates

NOTE:

Assemble the clutch dumper spring seat andthe clutch damper spring as shown.

First, install the friction plate and then alternatebetween the clutch plates and friction plates.

Clutch boss nut75 Nm (7.5 m•kg, 54 ft•lb)


New

New

1a56New

2

b

c4

3

6

5

1

New

New

TR..

Primary drive gear nut80 Nm (8.0 m•kg, 58 ft•lb)


2

1 3

TR..

CLUTCH

5-36

8. Install: Pressure plate Adjusting screw Pressure plate Clutch springs

NOTE:

Tighten the clutch spring bolts in two stages andin a crisscross pattern.

9. Check: Push lever position

Push lever mark “a” and crankcase mark “b”not aligned → Correct.

NOTE:

Move the push lever in the arrow direction withyour fingers, and check that it feels heavierwhen its mark aligns.

10.Adjust: Push lever position

a. Loosen the locknut “1”.b. Turn the adjusting screw “2” in or out until the

marks are aligned.c. Hold the adjusting screw to prevent it from

moving and then tighten the locknut to speci-fication.

CAUTION:

ECA13820

Do not overtighten the locknut since this willremove the free play between both pushrods.

11.Install: Clutch cover “1”

NOTE:

Tighten the bolts diagonally.

M6 × 25 mm bolt “2” M6 × 35 mm bolt “3” M6 × 50 mm bolt “4” M6 × 50 mm bolt (with gasket)“5” M6 × 55 mm bolt (with gasket)“6”

Adjusting screw lock nut8 Nm (0.8 m•kg, 5.8 ft•lb)

Clutch spring bolt8 Nm (0.8 m•kg, 5.8 ft•lb)

1 2

TR..

b

a


Clutch cover bolt10 Nm (1.0 m•kg, 7.2 ft•lb)

TR..

TR..

CLUTCH

5-37

12.Adjust: Clutch cable free play

Refer to “ADJUSTING THE CLUTCH CA-BLE FREE PLAY” on page 3-12.

1

2

6

454

2

2

2

22

2

23

OIL PUMP AND BALANCER GEAR

5-38

EAS3C51007


Removing oil pump and balancer gear


Primary drive gear Refer to “CLUTCH” on page 5-30.

1 Balancer driven gear nut 1

2 Lock washer 1

3 Buffer boss 1

4 Balancer driven gear 1

5 Absorber plate 1

6 Spring 6

7 Dowel pin 3

8 Straight key 1

9 Spacer 1

10 Circlip 1

11 Oil pump driven gear 1

12 Oil pump assembly 1

13 Oil pump gasket 1

14 Balancer drive gear 1

15 Oil strainer 1


ET

R..

55 Nm (5.5 m • kg, 40 ft • Ib)

TR..

6 Nm (0.6 m • kg, 4.3 ft • Ib)

1 2

11

37

12

13

4

5

8

6

915

14

10New

New

NewLT


5-39

Disassembling the oil pump


1 Oil pump cover 1

2 Dowel pin 1

3 Oil pump shaft 1

4 Dowel pin 2

5 Inner rotor 1

6 Outer rotor 1

7 Oil pump housing 1



5-40

EAS3C51008

REMOVING THE BALANCER GEAR1. Straighten the lock washer tab.2. Loosen:

Balancer driven gear unit “1”NOTE:

Insert aluminum plate “a” between balancerdrive gear “2” and balancer driven gear “3”, andloosen the balancer driven gear nut.

3. Remove: Balancer drive gear

Refer to “CLUTCH” on page 5-30.

EAS24960

CHECKING THE OIL PUMP1. Check:

Oil pump driven gear Oil pump housing Oil pump housing cover

Cracks/damage/wear → Replace the defec-tive part(s).

2. Measure: Inner-rotor-to-outer-rotor-tip clearance “a” Outer-rotor-to-oil-pump-housing clearance

“b” Oil-pump-housing-to-inner-rotor-and-out-

er-rotor clearance “c”Out of specification → Replace the oil pump.

3. Check: Oil pump operation

Rough movement → Repeat steps (1) and(2) or replace the defective part(s).

EAS24990

CHECKING THE OIL STRAINER1. Check:

Oil strainerDamage → Replace.Contaminants → Clean with solvent.

Inner-rotor-to-outer-rotor-tipclearance

0.150 mm (0.0059 in)Limit

0.200 mm (0.0079 in)Outer-rotor-to-oil-pump-housingclearance

0.100–0.151 mm (0.0039–0.0059in)

Limit0.221 mm (0.0087 in)

Oil-pump-housing-to-in-ner-and-outer-rotor clearance

0.04–0.09 mm (0.0016–0.0035 in)Limit

0.16 mm (0.0063 in)

1. Inner rotor

2. Outer rotor

3. Oil pump housing


5-41

EAS25000

ASSEMBLING THE OIL PUMP1. Lubricate:

Inner rotor Outer rotor Oil pump shaft


2. Install: Oil pump housing “1” Dowel pin Outer rotor “2” Inner rotor “3”

NOTE:

Align outer rotor mark “a” with inner rotor mark“b” and assemble them in the oil pump housing.

3. Install: Oil pump cover Oil pump shaft Dowel pin

NOTE:

When installing the oil pump cover, align thedowel pin of oil pump shaft with the inner rotorslot.

4. Check: Oil pump operation

Refer to “CHECKING THE OIL PUMP” onpage 5-40.

EAS3C51009

INSTALL THE OIL PUMP AND BALANCER GEAR1. Install:

Oil strainerNOTE:

Assemble the oil strainer in the crankcase in the

arrow direction as shown.

2. Install: Balancer drive gear

NOTE:

Direct the balancer drive gear mark outward ofthe vehicle during assembling.

3. Install: Oil pump gasket Oil pump

CAUTION:

ECA13890

After tightening the bolts, make sure the oilpump turns smoothly.

4. Install: Oil pump driven gear “1”

NOTE:

Direct stamp “a” of the oil pump driven gear out-ward of the vehicle.

5. Install: Balancer driven gear “1” Buffer boss “2” Dowel pin “3” Spring “4”

(To driven gear)NOTE:

Align mark “a” of the balancer driven gear withslot “b” of the buffer boss.


Oil pump cover screw7 Nm (0.7 m•kg, 5.1 ft•lb)

a

b

23

1

TR..

Oil pump bolt26 Nm (2.6 m•kg, 19 ft•lb)

New

TR..

1

a


5-42

Assemble the dowel pin on the spring asshown.

6. Install: Balancer driven gear “1” Lock washer Balancer driven gear nut

NOTE:

Align mark “a” of the balancer drive gear withmark “b” of the balancer driven gear.

7. Tighten: Primary drive gear nut

Refer to “CLUTCH” on page 5-30.8. Tighten:

Balancer driven gear nut “1”

NOTE:

Insert aluminum plate “a” between balancerdrive gear “2” and balancer driven gear “3”, andtighten the balancer driven gear nut.

9. Be sure to bend the lock washer tab along tothe nut side face.

Balancer driven gear nut55 Nm (5.5 m•kg, 40 ft•lb)

3

2

4

ba

1

New

TR..

SHIFT SHAFT

5-43

EAS25410

SHIFT SHAFTRemoving the shift shaft and stopper lever


Shift pedal assembly Refer to “ENGINE REMOVAL” on page 5-1.

Clutch housing Refer to “CLUTCH” on page 5-30.

1 Shift shaft assembly 1

2 Stopper lever 1

3 Stopper lever spring 1


LT

E

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

1

2

3

SHIFT SHAFT

5-44

EAS25420

CHECKING THE SHIFT SHAFT1. Check:

Shift shaft Shift lever

Bends/damage/wear → Replace. Shift lever spring


EAS25430

CHECKING THE STOPPER LEVER1. Check:

Stopper leverBends/damage → Replace.Roller turns roughly → Replace the stopperlever.

EAS25450

INSTALLING THE SHIFT SHAFT1. Install:

Stopper lever “1” Stopper lever spring

NOTE:

Hook the ends of the stopper lever spring ontothe stopper lever and the crankcase boss.

Mesh the stopper lever with the shift drum seg-ment assembly.

2. Install: Shift shaft assembly “1”

NOTE:

Align shaft spring “2” with stopper “3” and as-semble the shift shaft assembly.

Stopper lever bolt10 Nm (1.0 kg•m)Apply locking agent (LOC-TITE®)

TR..

1

1

23

GENERATOR AND STARTER CLUTCH

5-45

EAS3C51010


Removing the generator rotor and starter clutch


Drain the engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-11.

Rear left side coverRefer to “GENERAL CHASSIS” on page 4-1.

Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-57.

Shift pedal assembly Refer to “ENGINE REMOVAL” on page 5-1.

1 Pickup coil coupler/stator assembly coupler 1/1 Disconnect.

2 Starter clutch Idle gear cover 1

3 Starter clutch idle gear1 1

4 Starter clutch idle gear shaft1 1

5 Generator rotor cover 1

6 Generator rotor cover gasket 1

7 Dowel pin 2

8 Stator assembly 1

9 Starter clutch idle gear2 1

10 Starter clutch idle gear shaft2 1

11 Generator rotor 1

12 Woodruff key 1

13 Starter clutch gear 1

New

New

New

New

LTLT

E

LT

E

LT

New

E

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

30 Nm (3.0 m • kg, 22 ft • Ib)

TR..

60 Nm (6.0 m • kg, 43 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

1

2

3

4

5

6

8

9

(5)

(3)

(3)

(3)

7

10

11

13

14

12

15

(3)


5-46

14 Bearing 1

15 Starter clutch 1


Removing the generator rotor and starter clutch


New

New

New

New

LTLT

E

LT

E

LT

New

E

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

30 Nm (3.0 m • kg, 22 ft • Ib)

TR..

60 Nm (6.0 m • kg, 43 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

1

2

3

4

5

6

8

9

(5)

(3)

(3)

(3)

7

10

11

13

14

12

15

(3)


5-47

EAS24490

REMOVING THE GENERATOR1. Remove:

Generator rotor bolt “1” Washer

NOTE:

While holding the generator rotor “2” with thesheave holder “3”, loosen the generator rotorbolt.

Do not allow the sheave holder to touch theprojection on the generator rotor.

2. Remove: Generator rotor “1”

(with the flywheel puller “2” ) Woodruff key

CAUTION:

ECA13880

To protect the end of the crankshaft, placean appropriate sized socket between the fly-wheel puller set center bolt and the crank-shaft.

NOTE:

Make sure the flywheel puller is centered overthe generator rotor.

EAS24560

REMOVING THE STARTER CLUTCH1. Remove:

Starter clutch bolt “1”NOTE:

While holding the generator rotor “3” with thesheave holder “2”, remove the starter clutchbolt.


EAS24570

CHECKING THE STARTER CLUTCH1. Check:

Starter clutch rollersDamage/wear → Replace.

2. Check: Starter clutch idle gear 1, 2 Starter clutch gear

Burrs/chips/roughness/wear → Replace thedefective part(s).

3. Check: Starter clutch gear’s contacting surfaces

Damage/pitting/wear → Replace the starterclutch gear.

4. Check: Starter clutch operation

Sheave holder90890-01701

Primary clutch holderYS-01880-A

Flywheel puller90890-01362

Heavy duty pullerYU-33270-B

3

1

2



1

2

1

1 3

2


5-48

a. Install the starter clutch gear “1” onto thestarter clutch and hold the starter clutch.

b. When turning the starter clutch gear clock-wise “A”, the starter clutch and the starterclutch gear should engage, otherwise thestarter clutch is faulty and must be replaced.

c. When turning the starter clutch drive gearcounterclockwise “B”, it should turn freely,otherwise the starter clutch is faulty and mustbe replaced.

EAS24600

INSTALLING THE STARTER CLUTCH1. Install:

Starter clutch

NOTE:

While holding the generator rotor “2” with thesheave holder “1”, tighten the starter clutchbolt.


EAS24500

INSTALLING THE GENERATOR1. Install:

Woodruff key Generator rotor Washer Generator rotor bolt

NOTE:

Clean the tapered portion of the crankshaftand the generator rotor hub.

When installing the generator rotor, make surethe woodruff key is properly sealed in the key-way of the crankshaft.

2. Tighten: Generator rotor bolt “1”

NOTE:

While holding the generator rotor “2” with thesheave holder “3”, tighten the generator rotorbolt.


3. Install: Generator rotor cover “1”

Starter clutch bolt30 Nm (3.0 m•kg, 22 ft•lb)Apply locking agent (LOC-TITE®)



1A

B

TR..

Generator rotor bolt60 Nm (6.0 m•kg, 43 ft•lb)



TR..

3

1

2


5-49

NOTE:

Tighten the bolts diagonally.

M6 × 30 mm bolt “2” M6 × 40 mm bolt “3” M6 × 45 mm bolt “4”

Generator rotor cover bolt10 Nm (1.0 m•kg, 7.2 ft•lb)T

R..

ELECTRIC STARTER

5-50

EAS24780

ELECTRIC STARTERRemoving the starter motor


Carburetor Refer to “CARBURETOR” on page 6-3.

Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1.

1 Clutch cable holder 1

2 Starter motor lead 1 Disconnect.

3 Starter motor 1


TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

1

2

3

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

ELECTRIC STARTER

5-51

Disassembling the starter motor


1 Starter motor front cover 1

2 Lock washer 1

3 Armature assembly 1

4 Starter motor yoke 1

5 Starter motor rear cover 1

6 Brush 2

7 Brush spring 2


New

New

New

New

1

2

4

67

3

5

7

6

ELECTRIC STARTER

5-52

EAS24790

CHECKING THE STARTER MOTOR1. Check:

CommutatorDirt → Clean with 600 grit sandpaper.

2. Measure: Commutator diameter “a”

Out of specification → Replace the startermotor.

3. Measure: Mica undercut “a”

Out of specification → Scrape the mica to theproper measurement with a hacksaw bladethat has been grounded to fit the commuta-tor.

NOTE:

The mica of the commutator must be undercut toensure proper operation of the commutator.

4. Measure: Armature assembly resistances (commutator

and insulation)Out of specification → Replace the startermotor.

a. Measure the armature assembly resistances

with the pocket tester.

b. If any resistance is out of specification, re-place the starter motor.

5. Measure: Brush length “a”

Out of specification → Replace the brushesas a set.

6. Measure: Brush spring force

Out of specification → Replace the brushsprings as a set.

7. Check:


Mica undercut (depth)1.50 mm (0.06 in)


Armature coilCommutator resistance “1”

0.0126–0.0154 Ω at 20°C (68°F)Insulation resistance “2”

Above 1 MΩ at 20°C (68°F)


Brush spring force5.52–8.28 N (19.87–29.80 oz)(563–844 gf)

ELECTRIC STARTER

5-53

Gear teethDamage/wear → Replace the gear.

8. Check: Bearing Oil seal

Damage/wear → Replace the defectivepart(s).

EAS24800

ASSEMBLING THE STARTER MOTOR1. Install:

Lock washer “1”NOTE:

Align the tab “a” on the brush seat with the slot“b” in the starter motor rear cover.

2. Install: Starter motor yoke “1” Starter motor front cover “2” Starter motor rear cover “3”

NOTE:

Align the match marks on the starter motor yokewith the match marks on the front and startermotor rear covers.

1

ab

2 1 3

CRANKCASE

5-54

EAS25540

CRANKCASESeparating the crankcase


Engine Refer to “ENGINE REMOVAL” on page 5-1.

PistonRefer to “CYLINDER AND PISTON” on page 5-25.

Balancer drive gear Refer to “OIL PUMP AND BALANCER GEAR” on page 5-38.

Shift shaft Refer to “SHIFT SHAFT” on page 5-43.

Generator rotorRefer to “GENERATOR AND STARTER CLUTCH” on page 5-45.

1 Timing chain guide (intake side) 1

2 Timing chain 1

3 Crankshaft sprocket 1

4 Straight key 1

5 Speed sensor 1

6 Speed sensor rotor 1

7 Neutral switch 1

8 Right crankcase 1

9 Dowel pin 2

10 Left crankcase 1


New

New

New

New

LT

LT

TR..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

TR..

20 Nm (2.0 m • kg, 15 ft • Ib)

5

8

9 10

7

9

6

1

2

3

4

CRANKCASE

5-55

Removing the Bearing


Crankshaft assemblyRefer to “CRANKSHAFT ASSEMBLY” on page 5-58.

Main axle assembly/Drive axle assembly Refer to “TRANSMISSION” on page 5-61.

1 Bearing retainer 1

2 Oil seal 2

3 Bearing 7


E

E

E

E

E

LTLT

New

New

TR..

10 Nm (1.0 m • kg, 7.2 ft • Ib)

3

3

3

3

2

2

1

3

3

3

CRANKCASE

5-56

EAS25570

DISASSEMBLING THE CRANKCASE1. Remove:

Crankcase boltsNOTE:

Loosen each bolt 1/4 of a turn at a time, in twostages and in a crisscross pattern. After all of thebolts are fully loosened, remove them.

2. Turn: Shift drum segment

NOTE:

Turn the shift drum segment to the positionshown in the illustration. In this position, the shiftdrum segment’s teeth will not contact the crank-case during crankcase separation.

3. Remove: Right crankcase

CAUTION:

EC3C51004

Tap on one side the crankcase with asoft-face hammer. Tap only reinforced por-tions of the crankcase.

Do not damage the crankcase mating sur-faces.

Remove the crankcase right halves first.

EAS25580

CHECKING THE CRANKCASE1. Thoroughly wash the crankcase halves in a

mild solvent.2. Thoroughly clean all the gasket surfaces and

crankcase mating surfaces.3. Check:

CrankcaseCracks/damage → Replace.Obstruction → Blow out with compressed air.

EAS3C51011

CHECKING THE TIMING CHAIN, CRANKSHAFT SPROCKET, TIMING CHAIN GUIDE (INTAKE SIDE)1. Check:

Timing chain

Crack/stiffness → Replace the camshaftsprocket, timing chain, and crankshaftsprocket as a set.

2. Check: Crankshaft sprocket

Refer to “CYLINDER HEAD” on page 5-6.3. Check:

Timing chain guide (intake side)Damage/wear → Replace.

EAS3C51012

CHECKING THE BEARING AND OIL SEAL1. Check:

BearingAbnormal sound/rough movement/loose-ness → Replace.

2. Check: Oil seal


EAS25700

ASSEMBLING THE CRANKCASE1. Thoroughly clean all the gasket mating sur-

faces and crankcase mating surfaces.2. Apply:

Sealant(onto the crankcase mating surfaces)

NOTE:

Do not allow any sealant to come into contactwith the oil gallery.

3. Install: Right crankcase

(to the left crankcase)

NOTE:

Turn the shift drum segment as shown so thatthe shift drum segment teeth do not contact the

Yamaha bond No. 1215 (ThreeBond No.1215®)

90890-85505

Crankcase bolt10 Nm (1.0 m•kg, 7.2 ft•lb)T

R..

CRANKCASE

5-57

crankcase during its assembling. Tighten the bolts diagonally in two (2) stages,

with 1/4 turn each.

M6 × 70 mm bolt (with gasket)“1” M6 × 60 mm bolt “2” M6 × 55 mm bolt “3” M6 × 45 mm bolt “4”

4. Install: Crankshaft sprocket “1”

NOTE:

Assemble the crankshaft sprocket by facing itschamfered side “a” toward the crankcase.

a 1

CRANKSHAFT ASSEMBLY

5-58

EAS3C51013

CRANKSHAFT ASSEMBLY

Crankshaft assembly and balancer


Separate the crank case. Refer to “CRANKCASE” on page 5-54.

1 Balancer 1

2 Crankshaft assembly 1

3 Dowel pin 1

4 Plunger pin 1

5 Bearing 1


5

2

3

4

1

E

CRANKSHAFT ASSEMBLY

5-59

EAS26000

REMOVING THE CRANKSHAFT ASSEMBLY1. Remove:

Crankshaft assembly “1”NOTE:

Remove the crankshaft assembly using crank-shaft separating tool “2”.

2. Remove: Dowel pin “1” Plunger pin “2” Spring “3”

NOTE:

Slightly press the plunger pin and pull out thedowel pin. Then, remove the plunger pin and thespring.

EAS3C51014

CHECKING THE CRANKSHAFT AND CONNECTING ROD1. Measure:

Crankshaft runoutOut of specification → Replace the crank-shaft assembly, bearing or both.

NOTE:

Turn the crankshaft slowly.

2. Measure: Big end side clearance

Out of specification → Replace the crank-shaft assembly.

3. Measure: Crankshaft width

Out of specification → Replace the crank-shaft assembly.

4. Check: Bearing

Cracks/damage/wear → Replace the crank-shaft assembly.

5. Check: Crankshaft journal oil passage

Obstruction → Blow out with compressed air.

EAS26210

INSTALLING THE CRANKSHAFT ASSEMBLY1. Install:

Spring “1” Plunger pin “2” Dowel pin “3”

NOTE:

Press the plunger pin by your fingers, and makesure that it operates smoothly.

Crankcase separating tool90890-01135

Crankcase separatorYU-01135-B

Runout limit C0.030 mm (0.0012 in)

Big end side clearance D0.350–0.850 mm (0.0138–0.0335in)

Width A69.25–69.30 mm (2.726–2.728 in)

CRANKSHAFT ASSEMBLY

5-60

2. Install: Crankshaft assembly “1”

NOTE:

Install the crankshaft assembly using spacer “2”,adapter (M10) “3”, crankshaft installer “4”, andcrankshaft installer bolt “5”.

CAUTION:

ECA13970

To avoid scratching the crankshaft and toease the installation procedure, lubricate theoil seal lips with lithium-soap-based greaseand each bearing with engine oil.

NOTE:

Hold the connecting rod at top dead center(TDC) with one hand while turning the nut of thecrankshaft installer bolt with the other. Turn thecrankshaft installer bolt until the crankshaft as-sembly bottoms against the bearing.

Crankshaft installer pot90890-01274

Installing potYU-90058

Crankshaft installer bolt90890-01275

BoltYU-90060

Adapter (M10)90890-01383

Adapter #2YU-90062

Spacer90890-01288

TRANSMISSION

5-61

EAS26241

TRANSMISSIONRemoving the transmission, shift drum assembly, and shift forks


Crankcase separation Refer to “CRANKCASE” on page 5-54.

1 Shift fork guide bar 1

2 Shift drum assembly 1

3 Shift fork-R 1

4 Shift fork-C 1

5 Shift fork-L 1

6 Main axle assembly 1

7 Drive axle assembly 1


TRANSMISSION

5-62

Disassembling the transmission


1 2nd pinion gear 1

2 5th pinion gear 1

3 3rd/4th pinion gear 1

4 Main axle/1st pinion gear 1

5 Circlip 1

6 1st wheel gear 1

7 Dog clutch 1

8 Circlip 1

9 Lock washer 1

10 3rd wheel gear 1

11 4th wheel gear 1

12 5th wheel gear 1

13 Circlip 1

14 Lock washer 1

15 2nd wheel gear 1

16 Drive axle 1


TRANSMISSION

5-63

EAS26260

CHECKING THE SHIFT FORKSThe following procedure applies to all of the shiftforks.1. Check:

Shift fork cam follower “1” Shift fork pawl “2”

Bends/damage/scoring/wear → Replace theshift fork.

2. Check: Shift fork guide bar

Roll the shift fork guide bar on a flat surface.Bends → Replace.

WARNING

EWA12840

Do not attempt to straighten a bent shift forkguide bar.

3. Check: Shift fork movement

(along the shift fork guide bar)Rough movement → Replace the shift forksand shift fork guide bar as a set.

EAS26270

CHECKING THE SHIFT DRUM ASSEMBLY1. Check:

Shift drum grooveDamage/scratches/wear → Replace the shiftdrum assembly.

Shift drum segment “1”Damage/wear → Replace the shift drum as-sembly.

Shift drum bearing “2”Damage/pitting → Replace the shift drum as-sembly.

EAS26290

CHECKING THE TRANSMISSION1. Measure:

Main axle runout(with a centering device and dial gauge “1”)Out of specification → Replace the main axle.

2. Measure: Drive axle runout

(with a centering device and dial gauge “1”)Out of specification → Replace the drive axle.

Main axle runout limit0.08 mm (0.0032 in)

Drive axle runout limit0.08 mm (0.0032 in)

TRANSMISSION

5-64

3. Check: Transmission gears

Blue discoloration/pitting/wear → Replacethe defective gear(s).

Transmission gear dogsCracks/damage/wear → Replace the defec-tive gear(s).

4. Check: Transmission gear engagement

(each pinion gear to its respective wheelgear)Incorrect → Reassemble the transmissionaxle assemblies.

NOTE:

When reassembling the main axle “1”, press the2nd pinion gear “2” onto it as shown.

5. Check: Transmission gear movement

Rough movement → Replace the defectivepart(s).

6. Check: Circlips

Bends/damage/looseness → Replace.

EAS26320

INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY1. Install:

Shift fork-L “1” Shift fork-C Shift fork-R “2” Shift drum assembly “3” Shift fork guide bars “4”

NOTE:

The embossed marks (“R”/“C”/“L”) on the shiftforks should face towards the right side of theengine.

2. Check: Transmission

Rough movement → Repair.NOTE:

Oil each gear, shaft, and bearing thoroughly.

a. 102.2–102.4 mm

1

2

3

4

5

6

7

8

9

FUEL SYSTEM

FUEL TANK ...................................................................................................6-1CHECKING THE FUEL COCK.................................................................6-2

CARBURETOR ..............................................................................................6-3CHECKING THE CARBURETOR............................................................6-6ASSEMBLING THE CARBURETOR........................................................6-7INSTALLING THE CARBURETOR..........................................................6-8

AIR INDUCTION SYSTEM.............................................................................6-9CHECKING THE AIR INDUCTION SYSTEM ..........................................6-12

FUEL TANK

6-1

EAS26620

FUEL TANKRemoving the fuel tank


Left fuel tank side cover/right fuel tank side cover


1 Fuel hose 1 Disconnect.

2 Fuel tank 1

3 Fuel cock 1


TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

1

2

3

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

FUEL TANK

6-2

EAS26650

CHECKING THE FUEL COCK1. Check:

Fuel cockCracks/damage/wear → Replace.

2. Check: Fuel cock strainer “1”

Obstruction → clean.Blow out the jets with compressed air.Damage → Replace.

1

CARBURETOR

6-3

EAS26720

CARBURETORRemoving the carburetor



Air cut-off valveRefer to “AIR INDUCTION SYSTEM” on page 6-9.

1 Throttle cable 2

2 Starter plunger 1

3 Carburetor warmer coupler 1 Disconnect.

4 Fuel hose 1

5 Intake manifold clamp screw 1 Loosen.

6 Carburetor joint clamp screw 1 Loosen.

7 Air filter case bolt 1

8 Battery/electrical compornents box bolt 3

NOTE:Remove the air filter case bolts and the bat-

tery/electric parts box bolts, and then slide

both the air filter case and the battery/electric

parts box backward.

9 Carburetor assembly 1

10 Carburetor air vent hose 2

11 Carburetor fuel drain hose 1


LTLT

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

8

8

74

1

6

9

2

1011

5

10

3

CARBURETOR

6-4

Disassembling the carburetor


1 Throttle stop screw 1

2 Vacuum chamber cover 1

3 Piston valve spring 1

4 Jet needle holder 1

5 Spring 1

6 Jet needle kit 1

7 Piston valve 1

8 Coasting enricher cover 1

9 Coasting enricher spring 1

10 Coasting enricher diaphragm 1

11 Carburetor warmer lead 1

12 Carburetor warmer 1

13 Pilot screw set 1

14 Float chamber 1

15 Float chamber rubber gasket 1

16 Float pin 1

17 Float 1

18 Needle valve 1

19 Needle valve seat 1

20 Main jet 1

New

2

4

7

10

13

19

15

14

22

21

20

17

11

12

23

1

98

6

5

3

16

18

CARBURETOR

6-5

21 Main jet holder 1

22 Needle jet 1

23 Pilot jet 1


Disassembling the carburetor


New

2

4

7

10

13

19

15

14

22

21

20

17

11

12

23

1

98

6

5

3

16

18

CARBURETOR

6-6

EAS26760

CHECKING THE CARBURETOR1. Check:

Carburetor body Float chamber Jet housing


Fuel passagesObstruction → Clean.

a. Wash and clean the carburetor with a kero-sene. Never use a poor volatile carburetorcleaner.

b. Clean all carburetor passages by air blow.

3. Check: Float chamber body

Dirt → Clean.4. Check:

FloatDamage → Replace.

5. Check: Needle valve “1” Needle valve seat “2”

Damage/obstruction/wear → Replace theneedle valve and needle valve seat.

6. Check: Piston valve “1”

Damage/scratches/wear → Replace. Piston valve diaphragm “2”

Cracks/tears → Replace.

7. Check: Vacuum chamber cover Piston valve spring


Coasting enricher cover Coasting enricher spring Coasting enricher diaphragm


Jet needle holder “1”Cracks/damage → Replace.

Jet needle kit “2” Needle jet “3” Pilot screw set “4” Pilot jet “5” Main jet “6” Main jet holder “7”

Bends/damage/wear → Replace.Obstruction → Blow out with compressed air.

10.Check: Piston valve movement

Insert the piston valve into the carburetorbody and move it up and down.Tightness → Replace the piston valve.

11.Check: Starter plunger Starter plunger spring

Bends/cracks/damage → Replace.12.Check:

Hose joints

2

1

2

1

12

3

4

5 6

7

CARBURETOR

6-7

Cracks/damage → Replace.13.Check:

Carburetor air vent hose Carburetor fuel drain hose Fuel hoses

Cracks/damage/wear → Replace.Obstruction → Clean.Blow out the hoses with compressed air.

EAS26800

ASSEMBLING THE CARBURETOR

CAUTION:

ECA14110

Before assembling the carburetor, wash allof the parts in a petroleum-based solvent.

Always use a new gasket.

1. Install: Needle jet Main jet holder Main jet “1” Pilot jet “2” Needle valve seat “3”

2. Install: Needle valve Float “1” Float pin “2”

NOTE:

Install the float pin in the reverse direction of ar-row “a”.

3. Check: Float height (dimention H) “a”

Remove the float chamber rubber gasket,and measure the height from the float cham-

ber matching face to the float top face.

NOTE:

Temporarily lift the float, and check the oil levelwhen the needle valve end slightly touches thefloat tongue.

Out of specification → Bend the loat tongue“1” and adjust.

4. Install: Float chamber Pilot screw “1”

5. Install: Piston valve Jet needle holder Jet needle kit “1”

1

3

2

1

2

a

Float height11.9 mm (0.47 in)

Pilot screw turn out2–1/2

a

1

1

CARBURETOR

6-8

Clip position

EAS26890

INSTALLING THE CARBURETOR1. Adjust:

Engine idling speedRefer to “ADJUSTING THE ENGINE IDLINGSPEED” on page 3-8.


Refer to “ADJUSTING THE THROTTLE CA-BLE FREE PLAY” on page 3-9.

Standard clip position3 levels



12345

1

AIR INDUCTION SYSTEM

6-9

EAS27040


1 24

67

35


6-10

1. Cylinder head

2. Air induction system pipe

3. Air induction system hose (from the air cut-off valve to the cylinder head)

4. Air induction system vacuum hose

5. Air cut-off valve

6. Air induction system hose (from the air filter to the air cut-off valve)

7. Air filter case


6-11

Removing the air cut-off valve and hose



1 Air induction system vacuum hose 1

2Air induction system hose (from the air cut-off valve to the cylinder head)

1

3 Air cut-off valve 1

4Air induction system hose (from the air filter to the air cut-off valve)

1


TR..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

1

2

3

4


6-12

EAS27060

CHECKING THE AIR INDUCTION SYSTEMAir inductionThe air induction system burns unburned ex-haust gases by injecting fresh air (secondary air)into the exhaust port, reducing the emission ofcarbon monoxide. When there is negative pres-sure at the exhaust port, the reed valve opens,allowing secondary air to flow into the exhaustport. The required temperature for burning theunburned exhaust gases is approximately 600to 700°C.Air cut-off valveThe air cut-off valve is controlled by the intakegas pressure from the intake manifold. Ordinari-ly, the air cut-off valve opens to allow the air toflow during idle and closes to cut-off the flowwhen the vehicle is being driven. If the pressuredrops when the engine speed is high, theair-cutoff valve is closed automatically.

1. Check: Hoses

Loose connections → Connect properly.Cracks/damage → Replace.

PipesCracks/damage → Replace.Refer to “CYLINDER HEAD” on page 5-6.

2. Check: Air cut-off valve

Cracks/damage → Replace the reed valve.

A. From the air filter

B. From the intake manifold

C. To the cylinder head

A

B

C


6-13

1

2

3

4

5

6

7

8

9

ELECTRICAL SYSTEM

IGNITION SYSTEM ........................................................................................7-1CIRCUIT DIAGRAM.................................................................................7-1TROUBLESHOOTING .............................................................................7-3

ELECTRIC STARTING SYSTEM...................................................................7-5CIRCUIT DIAGRAM.................................................................................7-5STARTING CIRCUIT CUT-OFF SYSTEM OPERATION.........................7-7TROUBLESHOOTING .............................................................................7-9

CHARGING SYSTEM ....................................................................................7-11CIRCUIT DIAGRAM.................................................................................7-11TROUBLESHOOTING .............................................................................7-13

LIGHTING SYSTEM.......................................................................................7-15CIRCUIT DIAGRAM.................................................................................7-15TROUBLESHOOTING .............................................................................7-17

SIGNALING SYSTEM ....................................................................................7-19CIRCUIT DIAGRAM.................................................................................7-19TROUBLESHOOTING .............................................................................7-21

CARBURETOR HEATING SYSTEM .............................................................7-25CIRCUIT DIAGRAM.................................................................................7-25TROUBLESHOOTING .............................................................................7-27

ELECTRICAL COMPONENTS ......................................................................7-29CHECKING THE SWITCHES ..................................................................7-33CHECKING THE BULBS AND BULB SOCKETS ....................................7-36CHECKING THE FUSE............................................................................7-37CHECKING AND CHARGING THE BATTERY........................................7-37CHECKING THE RELAYS.......................................................................7-40CHECKING THE TURN SIGNAL RELAY ................................................7-41CHECKING THE DIODE..........................................................................7-42CHECKING THE SPARK PLUG CAP......................................................7-42CHECKING THE IGNITION COIL............................................................7-43CHECKING THE PICKUP COIL ..............................................................7-44CHECKING THE STATOR COIL .............................................................7-44CHECKING THE RECTIFIER/REGULATOR...........................................7-45CHECKING THE HORN...........................................................................7-45CHECKING THE SPEED SENSOR.........................................................7-46CHECKING THE THERMO SWITCH ......................................................7-46CHECKING THE CARBURETOR WARMER...........................................7-47

IGNITION SYSTEM

7-1

EAS27090

IGNITION SYSTEM

EAS27100

CIRCUIT DIAGRAM

W WWW WW

W WW

OF

FO

NO

FF

RU

N

OF

FL

OC

K

ON

Sb

Sb

Sb

Sb

Sb

WW

P

P

W

Dg

Ch

Dg

Dg

Ch

Ch

Ch

Dg

Ch

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Sb

Sb

Sb

Sb

Sb

W

Dg

Dg

Dg

Dg

B

Ch

Ch

Ch

Ch

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W

OO

Br

BB

BB

Br

Br

Br

L N RY

YY Y

Y

HI

LO

OF

FP

US

H

(RE

D)

(RE

D)

WW

W

WR

RR

BW B

W BW B

BB

B

BB

BB

B

BB

B B B

BBB

B

BB

B

B

B

B

Br

RR

Br

R

BB

WWW

WW

W

WW

W

Ch

Ch

Ch

Ch

Dg

Dg

Dg

Dg

BB

B

BBB

B

Y

G

B

B L

B

YY

Y

Br

BB

BB

BB

R/L

R/B

Br

G

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W/B

W/L

W/R

R/L

R/L

R/B

Br/

W

Br/

W

L/B

L/B

Lg

Lg

B/W

B/W

L/W

L/W

BB

BB

BB

B

R/W

R/W

R/W

B/W

R/W

L/W

L/Y

B/W

L/Y

L/Y

L/Y

L/B

L/B

R/W

Br

R/W

RR

RR

R R

RR

L/W

L/W L/B

L/B

L/B

Br/

WB

r/W

B/W

B/W

B/Y

B/Y

LL

YY

L/W

L/W

L/W

L/W

L/B

L/B

L/Y

L/B

L/B

B/W

B/W

B/W

O

W/L

W/R

W/B

R/L

R/G

R/G

R/L

R/W

Br

Br

W/R

W/B

PP

Lg Lg

B

Br/

W

Br/

L

G/Y

G/Y

B/Y

20A

L

YL

YL

LL

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

(BR

OW

N)

(BR

OW

N)

(BL

AC

K)

(GR

AY

)(G

RA

Y)

(GR

AY

)

(BL

AC

K)

(GR

AY

)

Y

Y

W/L

W/R

(BL

AC

K)

(BL

AC

K)

W/L

W/R

R/W

R/W

G/W

L/B

L/B

B/Y

B/Y

B/Y

B/Y

G/Y

G/Y

R/G

1 23

4

5

67

8

qw

e

ry

t

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p

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jh

k

l;

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vc

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9

0

#

$

%

BA

C

MA

IN H

AR

NE

SS

CA

RB

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RM

ER

MA

IN H

AR

NE

SS

SP

EE

D S

EN

SO

RM

AIN

HA

RN

ES

ST

AIL

LIG

HT

IGNITION SYSTEM

7-2

1. Pickup coil

2. A.C. magneto

4. Fuse

6. Battery

9. Main switch

10. Right handlebar switch

11. Engine stop switch

13. Diode

15. Sidestand switch


17. Diode 3

18. Neutral switch

19. C.D.I. unit

20. Ignition coil

21. Spark plug

IGNITION SYSTEM

7-3

EAS27130

TROUBLESHOOTINGThe ignition system fails to operate (no spark or intermittent spark).NOTE:

Before troubleshooting, remove the following part(s):1.Seat2.Rear side cover3.Tool box4.Fuel tank5.Carburetor assembly6.Starter (choke) knob

1. Check the fuse.Refer to “CHECKING THE FUSE” on page 7-37.

NG→ Replace the fuse(s).

OK↓

2. Check the battery.Refer to “CHECKING AND CHARG-ING THE BATTERY” on page 7-37.

NG→ Clean the battery terminals. Recharge or replace the battery.

OK↓

3. Check the spark plug.Refer to “CHECKING THE SPARK PLUG” on page 3-8.

NG→ Re-gap or replace the spark plug.

OK↓

4. Check the spark plug cap.Refer to “CHECKING THE SPARK PLUG CAP” on page 7-42.

NG→ Replace the spark plug cap.

OK↓

5. Check the ignition coil.Refer to “CHECKING THE IGNITION COIL” on page 7-43.

NG→ Replace the ignition coil.

OK↓

6. Check the pickup coil.Refer to “CHECKING THE PICKUP COIL” on page 7-44.

NG→ Replace the pickup coil/stator assembly.

OK↓

7. Check the stator coil.Refer to .

NG→ Replace the pickup coil/stator assembly.

OK↓

8. Check the main switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the main switch.

OK↓

9. Check the engine stop switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→Poor conducting of engine stop switch.Replace the right handlebar switch.

OK↓

IGNITION SYSTEM

7-4

10.Check the sidestand switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the sidestand switch.

OK↓

11.Check the clutch switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the clutch switch.

OK↓

12.Checking the entire ignition sys-tem’s wiring.Refer to “CIRCUIT DIAGRAM” on page 7-1.

NG→Properly connect or repair the ignitionsystem's wiring.

OK↓

Replace the C.D.I. unit.

ELECTRIC STARTING SYSTEM

7-5

EAS27160


EAS27170

CIRCUIT DIAGRAM

W WWW WW

W WW

OF

FO

NO

FF

RU

N

OF

FL

OC

K

ON

Sb

Sb

Sb

Sb

Sb

WW

P

P

W

Dg

Ch

Dg

Dg

Ch

Ch

Ch

Dg

Ch

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Sb

Sb

Sb

Sb

Sb

W

Dg

Dg

Dg

Dg

B

Ch

Ch

Ch

Ch

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W

OO

Br

BB

BB

Br

Br

Br

L N RY

YY Y

Y

HI

LO

OF

FP

US

H

(RE

D)

(RE

D)

WW

W

WR

RR

BW B

W BW B

BB

B

BB

BB

B

BB

B B B

BBB

B

BB

B

B

B

B

Br

RR

Br

R

BB

WWW

WW

W

WW

W

Ch

Ch

Ch

Ch

Dg

Dg

Dg

Dg

BB

B

BBB

B

Y

G

B

B L

B

YY

Y

Br

BB

BB

BB

R/L

R/B

Br

G

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W/B

W/L

W/R

R/L

R/L

R/B

Br/

W

Br/

W

L/B

L/B

Lg

Lg

B/W

B/W

L/W

L/W

BB

BB

BB

B

R/W

R/W

R/W

B/W

R/W

L/W

L/Y

B/W

L/Y

L/Y

L/Y

L/B

L/B

R/W

Br

R/W

RR

RR

R R

RR

L/W

L/W L/B

L/B

L/B

Br/

WB

r/W

B/W

B/W

B/Y

B/Y

LL

YY

L/W

L/W

L/W L/W

L/B

L/BL

/Y

L/B

L/B

B/W

B/W

B/W

O

W/L

W/R

W/B

R/L

R/G

R/G

R/L

R/W

Br

Br

W/R

W/B

PP

Lg Lg

B

Br/

W

Br/

L

G/Y

G/Y

B/Y

20A

L

YL

YL

LL

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

(BR

OW

N)

(BR

OW

N)

(BL

AC

K)

(GR

AY

)(G

RA

Y)

(GR

AY

)

(BL

AC

K)

(GR

AY

)

Y

Y

W/L

W/R

(BL

AC

K)

(BL

AC

K)

W/L

W/R

R/W

R/W

G/W

L/B

L/B

B/Y

B/Y

B/Y

B/Y

G/Y

G/Y

R/G

1 23

4

5

67

8

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BA

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SS

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RB

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RM

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AR

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SP

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EN

SO

RM

AIN

HA

RN

ES

ST

AIL

LIG

HT


7-6

4. Fuse

5. Starter relay

6. Battery

7. Starter motor

8. Diode 1

9. Main switch

10. Right handlebar switch


12. Start switch

13. Diode 2

14. Clutch switch

15. Sidestand switch


17. Diode 3

18. Neutral switch


7-7

EAS27180

STARTING CIRCUIT CUT-OFF SYSTEM OPERATIONIf the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), thestarter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the

sidestand switch is closed).The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach thestarter motor. If any of the above has occurred and if the starting circuit cut-off relay is turned ON, youcan start the engine by pressing starter switch “ ”.

2

7

3

5

6

a

b

4

1

8

10

9

11

12

13

14


7-8

a. WHEN THE TRANSMISSION IS IN NEU-TRAL

b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR

1. Battery

2. Fuse

3. Main switch

4. Diode2

5. Clutch switch

6. Sidestand switch


8. Neutral switch

9. Diode3


11. Start switch

12. Diode1

13. Starter relay

14. Starter motor


7-9

EAS27190

TROUBLESHOOTINGThe starter motor fails to turn.NOTE:

Before troubleshooting, remove the following part(s):1.Seat2.Rear side cover3.Tool box4.Fuel tank5.Carburetor assembly



OK↓



OK↓

3. Check the starter motor.Refer to “CHECKING THE STARTER MOTOR” on page 5-52.

NG→ Repair or replace the starter motor.

OK↓

4. Check the starting circuit cut-off relay.Refer to “CHECKING THE RELAYS”on page 7-40.

NG→ Replace the starting circuit cut-off relay.

OK↓

5. Check the diode2.Refer to “CHECKING THE DIODE” on page 7-42.

NG→ Replace the diode2.

OK↓

6. Check the diode3.Refer to “CHECKING THE DIODE” on page 7-42.

NG→ Replace the diode3.

OK↓

7. Check the starter relay.Refer to “CHECKING THE RELAYS”on page 7-40.

NG→ Replace the starter relay.

OK↓



OK↓

9. Checking the engine stop switch.Refer to “CHECKING THE SWITCHES” on page 7-33.


OK↓


7-10

10.Check the engine stop switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the right handlebar switch.

OK↓

11.Check the neutral switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the neutral switch.

OK↓

12.Check the sidestand switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the sidestand switch.

OK↓

13.Check the clutch switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the clutch switch.

OK↓

14.Check the start switch.Refer to “CHECKING THE SWITCHES” on page 7-33.


OK↓

15.Check the entire starting system’swiring.Refer to “CIRCUIT DIAGRAM” on page 7-5.

NG→Properly connect or repair the startingsystem’s wiring

OK↓

The starting system circuit is OK.

CHARGING SYSTEM

7-11

EAS27200

CHARGING SYSTEM

EAS27210

CIRCUIT DIAGRAM

W WWW WW

OF

FO

NO

FF

RU

N

OF

FL

OC

K

ON

Sb

P

P

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Sb

(B

W/B

W

Br

B

Br

Br

L N R

HI

LO

OF

FP

US

H

(RE

D)

(RE

D)

WW

W

WR

RR

W BW B

B B B

BBB

B

BB

B

B

Br

RR

Br

R

BB

WWW

WW

W

WW

W

Ch

Ch

Dg

Dg

BB

B L

B

Br

BB

BB

Br

(BLA

CK

)(B

LA

CK

)

W/B

Br/

W

Br/

W

L/B

L/B

Lg

Lg

L/W

L/W

BB

BB

BB

B

R/W

R/W

R/W

B/W

R/W

L/W

L/Y

L/Y

L/B

L/B

R/W

Br

R/W

RR

RR

R R

RR

L/W

L/W L/B

L/B

L/B

Br/

WB

r/W

B/W

B/W

L/W

L/W

L/W

L/W

L/B

L/B

L/Y

L/B

L/B

B/W

B/W

B/W

Br

Br

PP

Lg Lg

Br/

W

Br/

L

G/Y

G/Y

B/Y

20A

(BLA

CK

)(B

LA

CK

)(B

RO

WN

)(B

RO

WN

)

W/L

W/R

(BLA

CK

)

(BLA

CK

)

W/L

W/R

R/W

R/W

L/B

L/B

B/Y

B/Y

B/Y

B/Y

G/Y

G/Y

1 23

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IN

CHARGING SYSTEM

7-12

2. A.C. magneto


4. Fuse

6. Battery

CHARGING SYSTEM

7-13

EAS27220

TROUBLESHOOTINGThe battery is not being charged.NOTE:

Before troubleshooting, remove the following part(s):1.Seat2.Rear side cover3.Fuel tank4.Carburetor assembly


NG→ Replace the fuse.

OK↓



OK↓

3. Check the stator coil.Refer to “CHECKING THE STATOR COIL” on page 7-44.

NG→ Replace the stator assembly.

OK↓

4. Check the rectifier/regulator.Refer to “CHECKING THE RECTI-FIER/REGULATOR” on page 7-45.

NG→ Replace the rectifier/regulator.

OK↓

5. Check the entire charging system’swiring.Refer to “CIRCUIT DIAGRAM” on page 7-11.

NG→Properly connect or repair the chargingsystem’s wiring.

OK↓

This circuit is OK.

CHARGING SYSTEM

7-14

LIGHTING SYSTEM

7-15

EAS27240

LIGHTING SYSTEM

EAS27250

CIRCUIT DIAGRAM

W WWW WW

W WW

OF

FO

NO

FF

RU

N

OF

FL

OC

K

ON

Sb

Sb

Sb

Sb

Sb

WW

P

P

W

Dg

Ch

Dg

Dg

Ch

Ch

Ch

Dg

Ch

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Sb

Sb

Sb

Sb

Sb

W

Dg

Dg

Dg

Dg

B

Ch

Ch

Ch

Ch

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W

OO

Br

BB

BB

Br

Br

Br

L N RY

YY Y

Y

HI

LO

OF

FP

US

H

(RE

D)

(RE

D)

WW

W

WR

RR

BW B

W BW B

BB

B

BB

BB

B

BB

B B B

BBB

B

BB

B

B

B

B

Br

RR

Br

R

BB

WWW

WW

W

WW

W

Ch

Ch

Ch

Ch

Dg

Dg

Dg

Dg

BB

B

BBB

B

Y

G

B

B L

B

YY

Y

Br

BB

BB

BB

R/L

R/B

Br

G

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W/B

W/L

W/R

R/L

R/L

R/B

Br/

W

Br/

W

L/B

L/B

Lg

Lg

B/W

B/W

L/W

L/W

BB

BB

BB

B

R/W

R/W

R/W

B/W

R/W

L/W

L/Y

B/W

L/Y

L/Y

L/Y

L/B

L/B

R/W

Br

R/W

RR

RR

R R

RR

L/W

L/W L/B

L/B

L/B

Br/

WB

r/W

B/W

B/W

B/Y

B/Y

LL

YY

L/W

L/W

L/W

L/W

L/B

L/BL

/Y

L/B

L/B

B/W

B/W

B/W

O

W/L

W/R

W/B

R/L

R/G

R/G

R/L

R/W

Br

Br

W/R

W/B

PP

Lg Lg

B

Br/

W

Br/

L

G/Y

G/Y

B/Y

20A

L

YL

YL

LL

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

(BR

OW

N)

(BR

OW

N)

(BL

AC

K)

(GR

AY

)(G

RA

Y)

(GR

AY

)

(BL

AC

K)

(GR

AY

)

Y

Y

W/L

W/R

(BL

AC

K)

(BL

AC

K)

W/L

W/R

R/W

R/W

G/W

L/B

L/B

B/Y

B/Y

B/Y

B/Y

G/Y

G/Y

R/G

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HT

LIGHTING SYSTEM

7-16

4. Fuse

6. Battery

9. Main switch

19. C. D. I. unit

22. Meter assembly

26. High beam indicator light

29. Tail/brake light

31. Front turn signal light (right)

32. Front turn signal light (left)

34. Headlight

38. Headlight relay

40. Left handlebar switch

42. Dimmer switch

LIGHTING SYSTEM

7-17

EAS27260

TROUBLESHOOTINGAny of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light.NOTE:

Before troubleshooting, remove the following part(s):1.Seat2.Rear side cover3.Tool box

1. Check the each bulbs and bulb sockets condition.Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 7-36.

NG→ Replace the bulb(s), bulb socket(s) or both.

OK↓



OK↓



OK↓



OK↓

5. Check the dimmer switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→The dimmer switch is faulty. Replace the lefthandlebar switch.

OK↓

6. Check the headlight relay (on/off).Refer to “CHECKING THE RELAYS”on page 7-40.

NG→ Replace the headlight relay.

OK↓

7. Check the headlight relay (dimmer).Refer to “CHECKING THE RELAYS”on page 7-40.

NG→ Replace the headlight relay.

OK↓

8. Check the entire lighting system’swiring.Refer to “CIRCUIT DIAGRAM” on page 7-15.

NG→Properly connect or repair the lightingsystem’s wiring.

OK↓

This circuit is OK.

LIGHTING SYSTEM

7-18

SIGNALING SYSTEM

7-19

EAS27270

SIGNALING SYSTEM

EAS27280

CIRCUIT DIAGRAM

W WWW WW

W WW

OF

FO

NO

FF

RU

N

OF

FL

OC

K

ON

Sb

Sb

Sb

Sb

Sb

WW

P

P

W

Dg

Ch

Dg

Dg

Ch

Ch

Ch

Dg

Ch

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Sb

Sb

Sb

Sb

Sb

W

Dg

Dg

Dg

Dg

B

Ch

Ch

Ch

Ch

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W

OO

Br

BB

BB

Br

Br

Br

L N RY

YY Y

Y

HI

LO

OF

FP

US

H

(RE

D)

(RE

D)

WW

W

WR

RR

BW B

W BW B

BB

B

BB

BB

B

BB

B B B

BBB

B

BB

B

B

B

B

Br

RR

Br

R

BB

WWW

WW

W

WW

W

Ch

Ch

Ch

Ch

Dg

Dg

Dg

Dg

BB

B

BBB

B

Y

G

B

B L

B

YY

Y

Br

BB

BB

BB

R/L

R/B

Br

G

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W/B

W/L

W/R

R/L

R/L

R/B

Br/

W

Br/

W

L/B

L/B

Lg

Lg

B/W

B/W

L/W

L/W

BB

BB

BB

B

R/W

R/W

R/W

B/W

R/W

L/W

L/Y

B/W

L/Y

L/Y

L/Y

L/B

L/B

R/W

Br

R/W

RR

RR

R R

RR

L/W

L/W L/B

L/B

L/B

Br/

WB

r/W

B/W

B/W

B/Y

B/Y

LL

YY

L/W

L/W

L/W

L/W

L/B

L/BL

/Y

L/B

L/B

B/W

B/W

B/W

O

W/L

W/R

W/B

R/L

R/G

R/G

R/L

R/W

Br

Br

W/R

W/B

PP

Lg Lg

B

Br/

W

Br/

L

G/Y

G/Y

B/Y

20A

L

YL

YL

LL

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

(BR

OW

N)

(BR

OW

N)

(BL

AC

K)

(GR

AY

)(G

RA

Y)

(GR

AY

)

(BL

AC

K)

(GR

AY

)

Y

Y

W/L

W/R

(BL

AC

K)

(BL

AC

K)

W/L

W/R

R/W

R/W

G/W

L/B

L/B

B/Y

B/Y

B/Y

B/Y

G/Y

G/Y

R/G

1 23

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HT

SIGNALING SYSTEM

7-20

4. Fuse

6. Battery

9. Main switch

18. Neutral switch

19. C. D. I. unit

22. Meter assembly

23. Neutral indicator light

24. Multi-function display

25. Speedometer

27. Turn signal indicator light

28. Speed sensor

29. Tail/brake light

30. Rear turn signal light (right)

31. Front turn signal light (right)

32. Front turn signal light (left)

33. Rear turn signal light (left)


36. Front brake light switch

37. Turn signal relay

39. Horn

40. Left handlebar switch

41. Horn switch

43. Turn signal switch

SIGNALING SYSTEM

7-21

EAS27290

TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light or an indicator light. The horn fails to sound. The speedometer fails to operate.NOTE:

Before troubleshooting, remove the following part(s):1.Seat2.Rear side cover3.Tool box

Check the signaling system

The horn fails to sound.



OK↓



OK↓



OK↓

4. Check the entire signaling system’swiring.Refer to “CIRCUIT DIAGRAM” on page 7-19.

NG→Properly connect or repair the signalingsystem’s wiring.

OK↓

This circuit is OK.

1. Check the horn switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→Poor conducting of horn switch. Replace theleft handlebar switch.

OK↓

2. Check the horn.Refer to “CHECKING THE HORN” on page 7-45.

NG→ Replace the horn.

OK↓



OK↓

This circuit is OK.

SIGNALING SYSTEM

7-22

The tail/brake light fails to come on.

The turn signal light, turn signal indicator light or both fail to blink.

1. Check the tail/brake light bulb and socket.Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 7-36.

NG→Replace the tail/brake light bulb, socket orboth.

OK↓

2. Check the front brake light switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the front brake light switch.

OK↓

3. Check the rear brake light switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the rear brake light switch.

OK↓



OK↓

This circuit is OK.

1. Check the turn signal light bulb and socket.Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 7-36.

NG→Replace the turn signal light bulb, socket orboth.

OK↓

2. Check the turn signal switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→Poor conducting of turn signal switch.Replace the left handlebar switch.

OK↓

3. Check the turn signal relay.Refer to “CHECKING THE RELAYS”on page 7-40.

NG→ Replace the turn signal relay.

OK↓


NG→Properly connect or repair the signalingsystem's wiring.

OK↓

Meter assembly

SIGNALING SYSTEM

7-23

The neutral indicator light fails to come.

The speedometer fails to operate.

1. Check the neutral switch.Refer to “CHECKING THE SWITCHES” on page 7-33.

NG→ Replace the neutral switch.

OK↓



OK↓

This circuit is OK.

1. Check the speed sensor.Refer to “CHECKING THE SPEED SENSOR” on page 7-46.

NG→ Replace the speed sensor.

OK↓



OK↓

Replace the meter assembly.

SIGNALING SYSTEM

7-24

CARBURETOR HEATING SYSTEM

7-25

EAS27490


EAS27500

CIRCUIT DIAGRAM

W WWW WW

W WW

OF

FO

NO

FF

RU

N

OF

FL

OC

K

ON

Sb

Sb

Sb

Sb

W

P

P

W

Dg

Ch

Dg

Dg

Ch

Ch

Ch

Dg

Ch

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Sb

Sb

Sb

Sb

W

Dg

DB

Ch

G

(BL

AC

K)

(BL

AC

K)

W/B

W

Br

BB

BB

Br

Br

Br

L N RY

YY Y

Y

HI

LO

OF

FP

US

H

(RE

D)

(RE

D)

WW

W

WR

RR

BW B

W BW B

BB

B

BB

B B B

BBB

B

BB

B

B

B

Br

RR

Br

R

BB

WWW

WW

W

WW

W

Ch

Ch

Ch

Ch

Dg

Dg

Dg

Dg

BB

BY

G

B

B L

B

YY

Y

Br

BB

BB

R/L

R/B

Br

G

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W/B

W/L

W/R

R/L

R/B

Br/

W

Br/

W

L/B

L/B

Lg

Lg

B/W

L/W

L/W

BB

BB

BB

B

R/W

R/W

R/W

B/W

R/W

L/W

L/Y

L/Y

L/Y

L/Y

L/B

L/B

R/W

Br

R/W

RR

RR

R R

RR

L/W

L/W L/B

L/B

L/B

Br/

WB

r/W

B/W

B/W

B/Y

B/Y

L/W

L/W

L/W

L/W

L/B

L/BL

/Y

L/B

L/B

B/W

B/W

B/W

O

W/L

W/R

W/B

R/L

R/G

R/L

R/W

Br

Br

W/R

W/B

PP

Lg Lg

B

Br/

W

Br/

L

G/Y

G/Y

B/Y

20A

L

YL

YL

LL

(BL

AC

K)

(BL

AC

K)

(BR

OW

N)

(BR

OW

N)

(BL

AC

K)

(GR

AY

)(G

R

Y

W/L

W/R

(BL

AC

K)

(BL

AC

K)

W/L

W/R

R/W

R/W

G/W

L/B

L/B

B/Y

B/Y

B/Y

B/Y

G/Y

G/Y

R/G

1 23

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7-26

4. Fuse

6. Battery

9. Main switch

44. Thermo switch

45. Carburetor warmer


7-27

EAS27510

TROUBLESHOOTINGThe carburetor warmer system fails to operate.NOTE:

Before troubleshooting, remove the following part(s):1.Seat2.Rear side cover3.Tool box4.Fuel tank5.Carburetor assembly6.Rectifier/regulator



OK↓



OK↓



OK↓

4. Check the thermo switch.Refer to “CHECKING THE THERMO SWITCH” on page 7-46.

NG→ Replace the thermo switch.

OK↓

5. Check the carburetor warmer.Refer to “CHECKING THE CARBURE-TOR WARMER” on page 7-47.

NG→ Replace the carburetor warmer.

OK↓

6. Check the entire carburetor heating system’s wiring.Refer to “CIRCUIT DIAGRAM” on page 7-25.

NG→Properly connect or repair the carburetorheating system’s wiring.

OK↓

This circuit is OK.


7-28

ELECTRICAL COMPONENTS

7-29

EAS27971


EAS3C51017

2

3

4

7

5

8

10

12

1

11

13

6

9


7-30

1. Main switch

2. Diode1

3. Diode3

4. Diode2

5. Fuse

6. Starter relay

7. Battery


9. Sidestand switch


11. Headlight relay


13. Wire harness


7-31

2

1

8

95

4

3

7

6


7-32

1. Horn

2. CDI unit

3. Thermo switch

4. Speed sensor

5. Neutral switch

6. Carburetor warmer


8. Ignition coil

9. Spark plug cap


7-33

EAS27980

CHECKING THE SWITCHES

6

7

8

11

9

10

4

1

2

3

5

B B

Sb

Sb

Sb


7-34

1. Horn switch

2. Dimmer switch

3. Turn signal switch

4. Clutch switch

5. Sidestand switch

6. Main switch


8. Start switch

9. Front brake light switch

10. Neutral switch



7-35

Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check thewiring connections and if necessary, replace the switch.

CAUTION:

ECA14370

Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes fromthe opposite end of the coupler, taking care not to loosen or damage the leads.

NOTE:

Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range. When checking for continuity, switch back and forth between the switch positions a few times.

The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustra-tion similar to the one on below.The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in thetop row in the switch illustration.NOTE:

“ ” indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the re-spective switch position).

The example illustration below shows that:This chart shows that the switch circuit is conductive when the switch is “ON” for Red, Brown/Blue,Blue/Black, and Blue/Yellow.


ON

OFF

LOCK

a

b

R Br/L L/B L/Y

R Br/L

L/BL/Y


7-36

EAS27990

CHECKING THE BULBS AND BULB SOCKETSCheck each bulb and bulb socket for damage orwear, proper connections, and also for continu-ity between the terminals.Damage/wear → Repair or replace the bulb,bulb socket or both.Improperly connected → Properly connect.No continuity → Repair or replace the bulb, bulbsocket or both.Types of bulbsThe bulbs used on this vehicle are shown in theillustration on the left. Bulbs “a” and “b” are used for the headlights

and usually use a bulb holder that must be de-tached before removing the bulb. The majorityof these types of bulbs can be removed fromtheir respective socket by turning them coun-terclockwise.

Bulbs “c” is used for turn signal and tail/brakelights and can be removed from the socket bypushing and turning the bulb counterclock-wise.

Bulbs “d” and “e” are used for meter and indi-cator lights and can be removed from their re-spective socket by carefully pulling them out.

Checking the condition of the bulbsThe following procedure applies to all of thebulbs.1. Remove:

Bulb

WARNING

EWA13320

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

CAUTION:

ECA14380

Be sure to hold the socket firmly when re-moving the bulb. Never pull the lead, other-wise it may be pulled out of the terminal inthe coupler.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb, and the luminous flux will be adverse-ly affected. If the headlight bulb gets soiled,thoroughly it with a cloth moistened withalcohol or lacquer thinner.

2. Check: Bulb (for continuity)

(with the pocket tester)No continuity → Replace.

NOTE:

Before checking for continuity, set the pockettester to “0” and to the “Ω × 1” range.

a. Connect the positive tester probe to terminal“1” and the negative tester probe to terminal“2”, and check the continuity.

b. Connect the positive tester probe to terminal“1” and the negative tester probe to terminal“3”, and check the continuity.

c. If either of the readings indicate no continuity,replace the bulb.



7-37

Checking the condition of the bulb socketsThe following procedure applies to all of the bulbsockets.1. Check:

Bulb socket (for continuity)(with the pocket tester)No continuity → Replace.

NOTE:

Check each bulb socket for continuity in thesame manner as described in the bulb section;however, note the following.

a. Install a good bulb into the bulb socket.b. Connect the pocket tester probes to the re-

spective leads of the bulb socket.c. Check the bulb socket for continuity. If any of

the readings indicate no continuity, replacethe bulb socket.

EAS28000

CHECKING THE FUSEThe following procedure applies to all of thefuse.

CAUTION:

EC3C51005

To avoid a shortcircuit, disconnect the nega-tive battery lead from the battery terminal be-fore you check or replace the fuse.

1. Remove: Seat Rear right side cover

Refer to “GENERAL CHASSIS” on page 4-1.2. Check:

Fuse

a. Connect the pocket tester to the fuse andcheck the continuity.

NOTE:

Set the pocket tester selector to “Ω × 1”.

b. If the pocket tester indicates “∞”, replace thefuse.

3. Replace: Blown fuse

a. Set the main switch to “OFF”.b. Install a new fuse of the correct amperage

rating.c. Set on the switches to verify if the electrical

circuit is operational.d. If the fuse immediately blows again, check

the electrical circuit.

WARNING

EWA13310

Never use a fuse with an amperage ratingother than that specified. Improvising or us-ing a fuse with the wrong amperage ratingmay cause extensive damage to the electri-cal system, cause the lighting and ignitionsystems to malfunction and could possiblycause a fire.

4. Install: Rear right side cover Seat


EAS28030

CHECKING AND CHARGING THE BATTERY

WARNING

EWA13290

Batteries generate explosive hydrogen gasand contain electrolyte which is made of poi-sonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures: Wear protective eye gear when handling or

working near batteries. Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or

open flames (e.g., welding equipment,lighted cigarettes).

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTE



FuseAmperage

ratingQ’ty

Fuse 20 A 1

Reserve 20 A 1


7-38

OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it

can cause severe burns or permanent eyeinjury.

FIRST AID IN CASE OF BODILY CONTACT:EXTERNAL Skin — Wash with water. Eyes — Flush with water for 15 minutes and

get immediate medical attention.INTERNAL Drink large quantities of water or milk fol-

lowed with milk of magnesia, beaten egg orvegetable oil. Get immediate medical atten-tion.

CAUTION:

ECA13660

This is a sealed battery. Never remove thesealing caps because the balance betweencells will not be maintained and battery per-formance will deteriorate.

Charging time, charging amperage andcharging voltage for an MF battery are dif-ferent from those of conventional batteries.The MF battery should be charged as ex-plained in the charging method illustra-tions. If the battery is overcharged, theelectrolyte level will drop considerably.Therefore, take special care when chargingthe battery.

NOTE:

Since MF batteries are sealed, it is not possibleto check the charge state of the battery by mea-suring the specific gravity of the electrolyte.Therefore, the charge of the battery has to bechecked by measuring the voltage at the batteryterminals.

1. Remove: Seat Rear right side cover

Refer to “GENERAL CHASSIS” on page 4-1.2. Disconnect:

Battery band “1”Battery leads(from the battery terminals)

CAUTION:

EC3C51008

Always disconnect negative battery lead “2”first, and then disconnect positive batterylead “3”.

3. Remove: Battery

4. Check: Battery charge

a. Connect a pocket tester to the battery termi-nals.

NOTE:

The charge state of an MF battery can bechecked by measuring its open-circuit voltage(i.e., the voltage when the positive battery ter-minal is disconnected).

No charging is necessary when the open-cir-cuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown inthe charts and the following example.

5. Charge: Battery

(refer to the appropriate charging method il-lustration)

WARNING

EWA13300

Do not quick charge a battery.

CAUTION:

EC3C51007

Never remove the MF battery sealing caps. Do not use a high-rate battery charger.

They force a high-amperage current into

Positive tester probe →Positive battery terminalNegative tester probe →Negative battery terminal

ExampleOpen-circuit voltage = 12.0 VCharging time = 6.5 hoursCharge of the battery = 20–30%

2

1

3


7-39

the battery quickly and can cause batteryoverheating and battery plate damage.

If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.

Remove the battery when charging it. (Ifcharging has to be done with the batterymounted on the vehicle, disconnect thenegative lead from the battery terminal.)

To reduce the chance of sparks, do notplug in the battery charger until the batterycharger leads are connected to the battery.

Before removing the battery charger leadclips from the battery terminals, be sure toturn off the battery charger.

Make sure the battery charger lead clips arein full contact with the battery terminal andthat they are not shorted. A corroded bat-tery charger lead clip may generate heat inthe contact area and a weak clip spring maycause sparks.

When the battery is charging, if abnormalheat is generated, disconnect the batteryfrom the charger and allow the battery tocool down. Recharge the battery after itstemperature has dropped. Hot batteriescan explode!

The open-circuit voltage of a MF batterystabilizes about 30 minutes after charginghas been completed. Therefore, wait 30minutes after charging is completed beforemeasuring the open-circuit voltage.

Charging method using a variable-current(voltage) chargera. Measure the open-circuit voltage before

charging.NOTE:

Voltage should be measured 30 minutes afterthe machine is stopped.

b. Connect a charged and AMP meter to thebattery and start charging.

NOTE:

Set the charging voltage at 16–17 V.If the settingis lower, charging will be insufficient. If too high,the battery will be over-charged.

c. Make sure that the current is higher than thestandard charging current written on the bat-tery.

NOTE:

If the current is lower than the standard chargingcurrent written on the battery, set the charging

voltage adjust dial at 20–24 V and monitor theamperage for 3–5 minutes to check the battery.

d. Adjust the voltage so that the current is at thestandard charging level.

e. Set the time according to the charging timesuitable for the open-circuit voltage.Refer to “Battery condition checking steps”.

f. If charging requires more than 5 hours, it isadvisable to check the charging current aftera lapse of 5 hours. If there is any change inthe amperage, readjust the voltage to obtainthe standard charging current.

g. Measure the battery open-circuit voltage af-ter leaving the battery unused for more than30 minutes.

Charging method using a constant voltagechargera. Measure the open-circuit voltage before

charging.NOTE:

Voltage should be measured 30 minutes afterthe machine is stopped.

b. Connect a charger and AMP meter to the bat-tery and start charging.

c. Make sure that the current is higher than thestandard charging current written on the bat-tery.

NOTE:

If the current is lower than the standard chargingcurrent written on the battery, This type of bat-tery charger cannot charge the MF battery. Avariable voltage charger is recommended.

d. Charge the battery until the battery’s charg-ing voltage is 15 V.

NOTE:

Set the charging time at 20 hours (maximum).

e. Measure the battery open-circuit voltage af-

Reach the standard charging currentBattery is good.Does not reach the standard chargingcurrentReplace the battery.

12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is required.Under 12.0 V --- Replace the battery.


7-40

ter leaving the battery unused for more than30 minutes.

6. Install: Battery

7. Connect: Battery leads

(to the battery terminals)

CAUTION:

ECA13630

First, connect the positive battery lead “1”,and then the negative battery lead “2”.

8. Check: Battery terminals

Dirt → Clean with a wire brush.Loose connection → Connect properly.

9. Lubricate: Battery terminals

10.Install: Battery band

11.Install: Rear right side cover

SeatRefer to “GENERAL CHASSIS” on page 4-1.

EAS28040

CHECKING THE RELAYSCheck each switch for continuity with the pockettester. If the continuity reading is incorrect, re-place the relay.

1. Disconnect the relay from the wire harness.2. Connect the pocket tester (Ω × 1) and battery

(12 V) to the relay terminal as shown.Check the relay operation.Out of specification → Replace.

Starter relay

Starting circuit cut-off relay

12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is required.Under 12.0 V --- Replace the battery.

Recommended lubricantDielectric grease


2 1

1. Positive battery terminal

2. Negative battery terminal

3. Positive tester probe

4. Negative tester probe

ResultContinuity

(between “3” and “4”)





ResultContinuity(between “3” and “4”)

2 1

4

3

+

12

3

4


7-41

Headlight relay

EAS3C51015

CHECKING THE TURN SIGNAL RELAY1. Check:

Turn signal light relay input voltagesOut of specification → Poor circuit connectionfrom main switch to turn signal light relay cou-pler. Repair.

a. Connect the pocket tester (DC 20 V) to theturn signal light and hazard relay coupler asshown.

b. Turn the main switch “ON”.c. Measure the input voltage of the turn signal

light and hazard relay.

2. Check: Turn signal light and hazard relay output volt-

ageOut of specification → Replace the turn sig-nal light and hazard relay.

a. Touch probes of the pocket tester (DC 20 V)to the turn signal light and hazard relay cou-pler as shown.

b. Turn the main switch “ON”.c. Measure the output voltage of the turn signal

light and hazard relay.





ResultContinuity(between “3” and “4”)

Turn signal light relay input volt-age

DC 12 V


Positive probe of the testerBrown “1”Negative probe of the testerGround to chassis frame

+

12

3

4

Turn signal light and hazard relayoutput voltage

DC 12 V


Positive probe of the testerBrown/white “1”Negative probe of the testerGround to chassis frame


7-42

EAS28050

CHECKING THE DIODE1. Check:

Diode2 Diode3


NOTE:

The following lists the specifications if you usethe pocket tester (90890-03132).

a. Disconnect the diode from the wire harness.b. Connect the pocket tester (Ω × 1) to the diode

coupler as shown.c. Check the diode for continuity.d. Check the diode for no continuity.

EAS28060

CHECKING THE SPARK PLUG CAP1. Check:

Spark plug cap resistanceOut of specification → Replace.

a. Remove the spark plug cap from the sparkplug lead.

b. Connect the pocket tester (Ω × 1k) to thespark plug cap as shown.

c. Measure the spark plug cap resistance.


Diode2Continuity

Positive tester probe → Blue/white “1”Negative tester probe → Blue/black “2”

No continuityPositive tester probe → Blue/black “2”Negative tester probe → Blue/white “1”

Diode3Continuity

Positive tester probe → Sky blue“3”Negative tester probe → Lightgreen “4”

No continuityPositive tester probe → Lightgreen “4”Negative tester probe → Skyblue “3”

1

2

A

A. Diode2

B. Diode3

Resistance10.0 kΩ


3

4

B


7-43

EAS28090

CHECKING THE IGNITION COIL1. Check:

Primary coil resistanceOut of specification → Replace.

a. Disconnect the ignition coil connectors fromthe wire harness.

b. Connect the pocket tester (Ω × 1) to the igni-tion coil as shown.

c. Measure the primary coil resistance.

2. Check: Secondary coil resistance


a. Disconnect the spark plug cap from the igni-tion coil.

b. Connect the pocket tester (Ω × 1k) to the ig-nition coil as shown.

c. Measure the secondary coil resistance.

3. Check: Ignition spark gap

Out of specification → Follow Step 5 and laterof the ignition system troubleshooting proce-dure.Refer to “TROUBLESHOOTING” on page7-3.

a. Disconnect the spark plug cap from the sparkplug.

b. Connect ignition check “1” to the spark plugas shown.

Primary coil resistance0.18–0.27 Ω


Positive tester probeOrange “1”Negative tester probeIgnition coil base “2”

Secondary coil resistance6.32–9.48 kΩ


Positive tester probeHigh tension code “1”Negative tester probeOrange “2”

Minimum ignition spark gap6.0 mm

Ignition checker90890-06754

Opama pet-4000 spark checkerYM-34487


7-44

c. Turn the main switch “ON” and set the enginestop switch to the “ .

d. Measure ignition spark gap “a”.e. Press start switch “ ” to crank the engine,

and gradually increase the spark plug gapuntil the engine misfires.

EAS28110

CHECKING THE PICKUP COIL1. Disconnect:

Pickup coil coupler(from the wire harness)

2. Check: Pickup coil resistance

Out of specification → Replace the pickupcoil and stator assembly.

a. Connect the pocket tester (Ω × 100) to thepickup coil terminal as shown.

b. Measure the pickup coil resistance.

EAS28150

CHECKING THE STATOR COIL1. Disconnect:

Stator coil coupler(from the wire harness)

2. Check: Stator coil resistance

Out of specification → Replace the pickupcoil and stator assembly.

a. Connect the pocket tester (Ω × 1) to the statorcoil coupler as shown.

2. Spark plug cap

Pickup coil resistance279–341 Ω (Red–white)


Positive tester probeWhite “1”Negative tester probeRed “2”

Stator coil resistance0.560–0.840 Ω (White–white)


Positive tester probeWhite “1”Negative tester probeWhite “2”



12


7-45

b. Measure the stator coil resistance.

EAS28170

CHECKING THE RECTIFIER/REGULATOR1. Check:

Rectifier/regulator input voltageOut of specification → Replace the rectifier/regulator.

a. Connect a digital tachometer to the sparkplug lead of the cylinder.

b. Connect the pocket tester (DC 20 V) to therectifier/regulator coupler as shown.

c. Start the engine and let it run at approximate-ly 5000 r/min.

d. Measure the rectifier/regulator input voltage.

EAS28180

CHECKING THE HORN1. Check:

Horn resistanceOut of specification → Replace.

a. Disconnect the horn leads from the horn ter-minals.

b. Connect the pocket tester (Ω × 1) to the hornterminals.

c. Measure the horn resistance.

2. Check: Horn sound

Faulty sound → Adjust or replace.

a. Connect a battery (12 V) to the horn.b. Turn the adjusting screw in direction “a” or “b”

until the specified horn sound is obtained.

Rectifier/regulator input voltageabove 14 V at 5000 r/min


Positive tester probeRed “1”Negative tester probeGround to chassis frame

3

1

2

1

Horn resistance1.01–1.11 Ω at 20°C (68°F)


Positive tester probeHorn terminal “1”Negative tester probeHorn terminal “2”

1

2


7-46

EAS28240

CHECKING THE SPEED SENSOR1. Disconnect:

Speed sensor coupler2. Check:

Speed sensor resistanceOut of specification → Replace.

a. Connect the digital circuit tester to the speedsensor coupler (wire harness side).

b. Measure the speed sensor resistance.

EAS28270

CHECKING THE THERMO SWITCH1. Remove:

Thermo switch(from the thermostat housing)

WARNING

EWA13830

Handle the thermo switch with special care. Never subject the thermo switch to strong

shocks. If the thermo switch is dropped, re-place it.

2. Check: Thermo switch continuity

Out of specification → Replace the thermoswitch.

Step 1 and 2: Heating phaseStep 3 and 4: Cooling phase

a. Connect the pocket tester (Ω × 1) to the ther-mo switch “1” as shown.

b. Immerse the thermo switch in a containerfilled with coolant “2”.

c. Place a thermometer “3” in the coolant.

d. Slowly heat the coolant, then let it cool downto the specified temperature.

Speed sensor resistance470–530 Ω 25 °C (77 °F)

Digital circuit tester90890-03174

Model 88 Multimeter with tachom-eter

YU-A1927

Positive tester probeWhite “1”Negative tester probeBlack “2”

a b

21

Test step Coolant temperature Continuity

1 Less than 16°C (61°F) YES

2 More than 16°C (61°F) NO

3 More than 11°C (52°F) NO

4 Less than 11°C (52°F) YES


7-47

e. Check the thermo switch for continuity.

EAS28310

CHECKING THE CARBURETOR WARMER1. Check:

Carburetor warmer element resistanceOut of specification → Replace.

a. Remove the carburetor warmer leads fromthe carburetor.

b. Connect the pocket tester (Ω × 1) to the car-buretor warmer as shown.

c. Measure the carburetor warmer resistance.

A. When the water temperature increases

B. When the water temperature decreases

Carburetor warmer resistance4.7–9.5 Ω 20°C (68°F)


Positive tester probeCarburetor warmer terminal “1”Negative tester probeCarburetor warmer body “2”

1

2

3

4

5

6

7

8

9

TROUBLESHOOTING

TROUBLESHOOTING ...................................................................................8-1GENERAL INFORMATION......................................................................8-1STARTING FAILURES.............................................................................8-1INCORRECT ENGINE IDLING SPEED...................................................8-1POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE..........................8-2FAULTY GEAR SHIFTING.......................................................................8-2SHIFT PEDAL DOES NOT MOVE...........................................................8-2JUMPS OUT OF GEAR ...........................................................................8-2FAULTY CLUTCH....................................................................................8-2OVERHEATING .......................................................................................8-3POOR BRAKING PERFORMANCE.........................................................8-3FAULTY FRONT FORK LEGS.................................................................8-3UNSTABLE HANDLING...........................................................................8-3FAULTY LIGHTING OR SIGNALING SYSTEM.......................................8-3

TROUBLESHOOTING

8-1

EAS28450

TROUBLESHOOTING

EAS28460

GENERAL INFORMATIONNOTE:

The following guide for troubleshooting does notcover all the possible causes of trouble. It shouldbe helpful, however, as a guide to basic trouble-shooting. Refer to the relative procedure in thismanual for checks, adjustments, and replace-ment of parts.

EAS28470

STARTING FAILURESEngine1. Cylinder(s) and cylinder head(s)

Loose spark plug Loose cylinder head or cylinder Damaged cylinder head gasket Damaged cylinder gasket Worn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timing Faulty valve spring Seized valve

2. Piston(s) and piston ring(s) Improperly installed piston ring Damaged, worn or fatigued piston ring Seized piston ring Seized or damaged piston

3. Air filter Improperly installed air filter Clogged air filter element

4. Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft

Fuel system1. Fuel tank

Empty fuel tank Clogged fuel filter Clogged fuel strainer Clogged fuel tank drain hose Clogged rollover valve Clogged rollover valve hose Deteriorated or contaminated fuel

2. Fuel pump Faulty fuel pump Faulty fuel pump relay

3. Fuel cock Clogged or damaged fuel hose

4. Carburetor(s)

Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked-in air Damaged float Worn needle valve Improperly installed needle valve seat Incorrect fuel level Improperly installed pilot jet Clogged starter jet Faulty starter plunger Improperly adjusted starter cable

Electrical system1. Battery

Discharged battery Faulty battery

2. Fuse(s) Blown, damaged or incorrect fuse Improperly installed fuse

3. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap

4. Ignition coil(s) Cracked or broken ignition coil body Broken or shorted primary or secondary coils Faulty spark plug lead

5. Ignition system Faulty ignitor unit Faulty pickup coil Broken generator rotor woodruff key

6. Switches and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty sidestand switch Faulty clutch switch Improperly grounded circuit Loose connections

7. Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut-off relay Faulty starter clutch

EAS28490

INCORRECT ENGINE IDLING SPEEDEngine1. Cylinder(s) and cylinder head(s)

TROUBLESHOOTING

8-2

Incorrect valve clearance Damaged valve train components

2. Air filter Clogged air filter element

Fuel system1. Carburetor(s)

Faulty starter plunger Loose or clogged pilot jet Loose or clogged pilot air jet Damaged or loose carburetor joint Improperly synchronized carburetors Improperly adjusted engine idling speed

(throttle stop screw) Improper throttle cable free play Flooded carburetor Faulty air induction system

Electrical system1. Battery

Discharged battery Faulty battery

2. Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap

3. Ignition coil(s) Broken or shorted primary or secondary coils Faulty spark plug lead Cracked or broken ignition coil

4. Ignition system Faulty ignitor unit Faulty pickup coil Broken generator rotor woodruff key

EAS28520

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCERefer to “STARTING FAILURES” on page 8-1.Engine1. Air filter

Clogged air filter element2. Air intake system

Bent, clogged or disconnected carburetor airvent hose

Clogged or leaking air ductFuel system1. Carburetor(s)

Faulty diaphragm Incorrect fuel level Loose or clogged main jet

2. Fuel pump Faulty fuel pump

EAS28530

FAULTY GEAR SHIFTINGShifting is difficultRefer to “Clutch drags”.

EAS28540

SHIFT PEDAL DOES NOT MOVEShift shaft Improperly adjusted shift rod Bent shift shaftShift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide barTransmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission

EAS28550

JUMPS OUT OF GEARShift shaft Incorrect shift pedal position Improperly returned stopper leverShift forks Worn shift forkShift drum Incorrect axial play Worn shift drum grooveTransmission Worn gear dog

EAS28560

FAULTY CLUTCHClutch slips1. Clutch

Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate

2. Engine oil Incorrect oil level Incorrect oil viscosity (low) Deteriorated oil

Clutch drags1. Clutch

Unevenly tensioned clutch springs Warped pressure plate Bent clutch plate Swollen friction plate Bent clutch push rod Broken clutch boss Burnt primary driven gear bushing Match marks not aligned

2. Engine oil

TROUBLESHOOTING

8-3

Incorrect oil level Incorrect oil viscosity (high) Deteriorated oil

EAS28590

OVERHEATINGEngine1. Cylinder head(s) and piston(s)

Heavy carbon buildup2. Engine oil

Incorrect oil level Incorrect oil viscosity Inferior oil quality

Fuel system1. Carburetor(s)

Incorrect main jet setting Incorrect fuel level Damaged or loose carburetor joint

2. Air filter Clogged air filter element

Chassis1. Brake(s)

Dragging brakeElectrical system1. Spark plug(s)

Incorrect spark plug gap Incorrect spark plug heat range

2. Ignition system Faulty ignitor unit

EAS28620

POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose the union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level

EAS28660

FAULTY FRONT FORK LEGSLeaking oil Bent, damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level (high) Loose damper rod assembly bolt Damaged damper rod assembly bolt copper

washer

Cracked or damaged cap bolt O-ringMalfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damaged outer tube bushing Bent or damaged damper rod Incorrect oil viscosity Incorrect oil level

EAS28690

UNSTABLE HANDLING1. Handlebar

Bent or improperly installed handlebar2. Steering head components

Improperly installed upper bracket Improperly installed lower bracket

(improperly tightened ring nut) Bent steering stem Damaged ball bearing or bearing race

3. Front fork leg(s) Uneven oil levels (both front fork legs) Unevenly tensioned fork spring (both front

fork legs) Broken fork spring Bent or damaged inner tube Bent or damaged outer tube

4. Swingarm Worn bearing or bushing Bent or damaged swingarm

5. Rear shock absorber assembly(-ies) Faulty rear shock absorber spring Leaking oil or gas

6. Tire(s) Uneven tire pressures (front and rear) Incorrect tire pressure Uneven tire wear

7. Wheel(s) Incorrect wheel balance Broken or loose spoke Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout

8. Frame Bent frame Damaged steering head pipe Improperly installed bearing race

EAS28710

FAULTY LIGHTING OR SIGNALING SYSTEMHeadlight does not come on Wrong headlight bulb Too many electrical accessories Hard charging

TROUBLESHOOTING

8-4

Incorrect connection Improperly grounded circuit Poor contacts (main or light switch) Burnt-out headlight bulbHeadlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier/regulator Improperly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expiredTail/brake light does not come on Wrong tail/brake light bulb Too many electrical accessories Incorrect connection Burnt-out tail/brake light bulbTail/brake light bulb burnt out Wrong tail/brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail/brake light bulb life expiredTurn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt-out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown, damaged or incorrect fuseTurn signal blinks slowly Faulty turn signal relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulbTurn signal remains lit Faulty turn signal relay Burnt-out turn signal bulbTurn signal blinks quickly Incorrect turn signal bulb Faulty turn signal relay Burnt-out turn signal bulbHorn does not sound Improperly adjusted horn Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery Blown, damaged or incorrect fuse Faulty wire harness

EAS28740

WIRING DIAGRAM

XT250X/XT250XC 2008

1.Pickup coil2.A.C. magneto3.Rectifier/regulator4.Fuse5.Starter relay6.Battery7.Starter motor8.Diode 19.Main switch10.Right handlebar switch11.Engine stop switch12.Start switch13.Diode 214.Clutch switch15.Sidestand switch16.Starting circuit cut-off relay17.Diode 318.Neutral switch19.C. D. I. unit20.Ignition coil21.Spark plug22.Meter assembly23.Neutral indicator light24.Multi-function display25.Speedometer26.High beam indicator light27.Turn signal indicator light28.Speed sensor29.Tail/brake light30.Rear turn signal light (right)31.Front turn signal light (right)32.Front turn signal light (left)33.Rear turn signal light (left)34.Headlight35.Rear brake light switch36.Front brake light switch37.Turn signal relay38.Headlight relay39.Horn40.Left handlebar switch41.Horn switch42.Dimmer switch43.Turn signal switch44.Thermo switch45.Carburetor warmer

EAS28750

COLOR CODE

B Black

Br Brown

Ch Chocolate

Dg Dark green

G Green

Gy Gray

L Blue

O Orange

P Pink

R Red

Sb Sky blue

W White

Y Yellow

B/G Black/Green

B/L Black/Blue

B/R Black/Red

B/W Black/White

B/Y Black/Yellow

Br/G Brown/Green

Br/L Brown/Blue

Br/R Brown/Red

Br/W Brown/White

G/B Green/Black

G/R Green/Red

G/W Green/White

G/Y Green/Yellow

Gy/G Gray/Green

Gy/R Gray/Red

L/B Blue/Black

L/R Blue/Red

L/W Blue/White

L/Y Blue/Yellow

O/B Orange/Black

P/W Pink/White

R/B Red/Black

R/G Red/Green

R/L Red/Blue

R/W Red/White

R/Y Red/Yellow

Sb/W Sky blue/White

W/B White/Black

W/R White/Red

W/Y White/Yellow

Y/B Yellow/Black

Y/G Yellow/Green

Y/L Yellow/Blue

Y/R Yellow/Red

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

PRINTED IN U.S.A.

W WWW WW

W WW

OF

FO

NO

FF

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FL

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K

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Sb

WW

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P

W

Dg

Ch

Dg

Dg

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Dg

Ch

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Br

Sb

Sb

Sb

Sb

Sb

W

Dg

Dg

Dg

Dg

B

Ch

Ch

Ch

Ch

G

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

(BL

AC

K)

W/B

W

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Br

BB

BB

Br

Br

Br

L N RY

YY Y

Y

HI

LO

OF

FP

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(RE

D)

(RE

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WW

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ServiceManual - RAWRATS.COM · This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics.

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